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78 GS1000E Shifting Problems

  • Thread starter Thread starter dluszcz
  • Start date Start date
D

dluszcz

Guest
After getting the engine to turn over and run, I went to try the clutch and found that I can only go from neutral to 1st gear back to neutral, but not any of the upper gears.

I hit the starter button to turn the motor over and now I can't get it into 1st gear, but I can go from neutral to 2nd to 3rd gear.

I hit the starter button again and back to the 1st gear and neutral only.

I haven't been able to get it into 4th or 5th gear.

Any ideas on how to tackle this? I searched a bunch of threads and I haven't seen a problem like this completely.

I did have the clutch cable on at 1st but took it off to eliminate it from the equation. The bar where the clutch cable hooks up to is in the fully released position. When I move that bar, it doesn't make any difference.

The only time change in status occurs is when I hit the starter button. I do not have the chain and rear tire on, if that makes a difference.
 
Okay, you really need to properly hook up your clutch cable and arm so as to disengage the clutch to shift and try that

You're needlessly looking for problems
 
Hi,

I agree. Put it all back together (clutch, sprockets, chain, tires, etc) and adjust it according to your manual. Then you can properly troubleshoot.


Thank you for your indulgence,

BassCliff
 
OK, I will do that. Thanks for the advice. Maybe I won't need to add to this once I finish putting it back together.

Just getting ahead of myself. This warm weather makes me want to rush to get it done and on the road.
 
dluszcz said:
After getting the engine to turn over and run, I went to try the clutch and found that I can only go from neutral to 1st gear back to neutral, but not any of the upper gears.

I hit the starter button to turn the motor over and now I can't get it into 1st gear, but I can go from neutral to 2nd to 3rd gear.

I hit the starter button again and back to the 1st gear and neutral only.

I haven't been able to get it into 4th or 5th gear.

Any ideas on how to tackle this? I searched a bunch of threads and I haven't seen a problem like this completely.

I did have the clutch cable on at 1st but took it off to eliminate it from the equation. The bar where the clutch cable hooks up to is in the fully released position. When I move that bar, it doesn't make any difference.

The only time change in status occurs is when I hit the starter button. I do not have the chain and rear tire on, if that makes a difference.
Click to expand...

The tranmission needs to be turning(ie when hitting the starter button) to shift most of the time but in all probability have nothing wrong get the chain on and try it....
 
OK, today I got her running. Rear tire and chain on, clutch cable on and started her up and burnt all the webs and oils off the header pipes.

Tried to put it in 1st gear and when I pulled the clutch in, felt like too much play. Dumped it into 1st anyway and killed the motor.

Tried to pull it back up to neutral and couldn't. Hit the starter button a couple of times and was able to get it up to neutral.

Started the engine again popped it back into 1st gear. Killed it again and can't seem to get the clutch to disengage.

I left it in 1st gear and tried a couple of ways to get the clutch to disengage so the bike would roll freely. No luck.

Adjusted the clutch cable as per the manual. Nice and tight now and still not able to get the clutch to disengage.

Any ideas or is my clutch shot?
 
Last edited:
Sounds like the clutch has frozen after standing. Stick the bike in second, off the stand, apply both brakes and try the starter without pulling the clutch in.

Be prepared to hit the kill switch if the clutch doesn't free and the motor fires up.
 
I put it in 2nd gear, had both brakes applied, and hit the starter.

Didn't free it up. I'm starting to think I need a new clutch. Sure would hate to have to do that.

I keep reading threads about a clutch basket. I can't find that in my Haynes manual. What is it?

I still have the old engine that is blown and I can take that apart and possibly swap clutches. Good idea?
 
Upon doing more research, I was able to find a pic of the clutch basket on BassCliff's website in the Clutch Odds and Ends section from an 1100E.

I'm still not sure what I would need to file off or why my clutch will not engage or disengage, whichever it is.

Either way, it seems to be frozen and this motor hasn't been sitting for a long period of time, that I'm aware of.

I just do not know really where to start to solve this particular problem.
 
1st, ride it around the block about 50 times, pulling in the clutch periodically and braking

The most likely explanation is that your clutch plates are stuck together. Some torque, hot oil and braking should pop them loose
 
I didn't ride around the block 50 times but I rode around it about a dozen times and no matter what I try, I don't think I can free them up.

I can power shift up and down with no problem but I can't get the lever to work. Got as high as 4th gear on my tiny little side streets.

Since I have no lights hooked up yet, I don't want to push my luck with the local cops.

Once I'm in gear, all seems to function well.
 
Last edited:
Still at a loss for what is going on with my clutch.

I cannot seem to get it to disengage. Does this mean the clutch is shot?

If I have to tear it apart, what should I buy to rebuild it correctly?

I don't think the plates are shot since I can power shift, at least up to 4th gear.

Anybody have this problem and if so, did they get lucky and free up the plates by putting the bike in 1st gear with the tires on the ground and rocking it back and forth while the clutch is pulled?

Any other suggestions?
 
Last edited:
Hi,

Most of the time, if you take the plates out, separate them, clean the steels and rough up the fibers a little, make sure the basket is smooth, then reassemble, you should be OK. As long as you're there, you might as well replace the springs. Use OEM replacements. Check your manual for the service limit and measure the steels and fibers for wear before reassembly. I think you've already found a few pictures HERE.

When you do all this, you might as well replace the lousy phillips head bolts with a nice allen head stainless steel bolt set. I got my set from Z1.


Thank you for your indulgence,

BassCliff
 
dluszcz said:
Still at a loss for what is going on with my clutch.

I cannot seem to get it to disengage. Does this mean the clutch is shot?

If I have to tear it apart, what should I buy to rebuild it correctly?

I don't think the plates are shot since I can power shift, at least up to 4th gear.

Anybody have this problem and if so, did they get lucky and free up the plates by putting the bike in 1st gear with the tires on the ground and rocking it back and forth while the clutch is pulled?

Any other suggestions?
Click to expand...

Not shot, just stuck together

Do as Basscliff suggests and see what happens
 
I called the local Suzuki dealership to order the springs and clutch cover gasket and he gave me a couple more possible solutions.

1. Put the front tire against a strong wall, with the bike in gear and running, pull the clutch lever in and rev it up a little bit. The rear tire must be on pavement for friction and that may free it up.

2. Put the bike on the center stand close to said strong wall, start it up and keep it running in gear. Pull the lever in and give it a twist on the throttle and push it off the center stand.

The shock from either method should be enough to free up the plates.

He said DO NOT drop it from neutral to 1st gear unless I want metal to come out. He had a similar problem with his KZ that sat for 12 years and putting it against a wall and revving it up freed up his plates.

Anyone here know of anyone trying that? I'd really like to avoid taking the clutch apart if I can.
 
If you attempt one of these methods, please make a video of it for entertainment purposes. :)
 
The easiest way to free stuck plates is to ride around in first gear, pull the clutch in, and start cracking the throttle open and closed. Get the chain snatch going good. They will break free in no time.
 
I don't think either of those will work for you without disasterous results

Keeping riding it around in one gear ,speeding up, then letting off the throttle with the clutch pulled in
 
I've done another dozen or so laps tonight with the clutch lever pulled in and revving it up. Almost got a wheelie a couple of times and still not broken free.

I may end up taking it apart after all.

I have to buy more gas and do it again this weekend. I'll post results and or video if I'm dumb enough to put it against the wall.
 
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