Major Help Needed-Chain tried to kill me (Now with pics)

[BaoQingTian]

I'm coming home from work yesterday, turn into a parking lot, going about 30 or so, all of a sudden I hear a click, my back tire locks up, and my engine dies.  The guys at the Jiffy Lube saw my back tire leave th eground about 6 inches, and thought I was going down for sure.  I didn't, but I did leave a prett cool 25 foot skid mark.  My chain had left the rear sprocket- it didn't break entirely, but it mostly broke 1 link.  It was jammed between the sprocket and the bar, so that I couldn't move the bike.  It sheared the tips off two of the sprocket bolts, gauged and bent the bar just a little.  I had to force it off the sprocket to move it.  My clutch lever is completely slack.  I also wasn't able to move the shifter to find neutral.

So I had it towed home, and now I need to know what to look for.  I lost my stupid clymer manual, so any help I could get would be great.  I think I know what to take off, but I don't know what to look for for damage.  Obviously I'll want to replace the chain and both sprockets.  Is the clutch dead, tranny dead?   Any help would be MUCH appreciated.

[galahs]

Wow, glad you and the GS are alright.

I'm interested in what caused this too 

[MarkusN]

The chain probably broke the clutch pushrod. Might also have broken the clutch actuating screwy thingamajig.
Take off the sprocket cover, then you'll know more.

[BaoQingTian]

i'll take it off and post some pics

[red_phil]

when my chain went it took out the clutch push rod.
That makes your clutch go all slack.

I lucked out and my chain came off completely so this didn't cause my rear tire to lock up like yours did.

[galahs]

is having your chain snap a common problem?

how many k's (or miles) were on your bikes?

[BaoQingTian]

18300 miles.  I bought it 1000 miles ago, rebuilt carbs, changed fork seals, spark plugs, air box, etc.  I would guess it was probably the original chain.  Chain and sprockets were next on my to do list anyway.  Now it looks like I'll probably need a new clutch pushrod.  How much does that cost?

[scratch]

is having your chain snap a common problem?

It would only be common if you buy cheap chains and don't clean, lubricate and adjust regularily.  Mostly, it's just the lack of cleaning, lubricating and proper adjustment.

Remember: .8 to 1.2 inches of slack.  Too tight will contribute to chain failure.

[Kerry]

[...] I'll probably need a new clutch pushrod.  How much does that cost?

I could list some prices for the part, but it's probably better if you check them out yourself.  Look under the CLUTCH section of each of the vendors listed HERE.  As you get into the bike and assess the damage, you may find that other parts need to be replaced too, and you'll be able to price them yourself.

PS - If you're in any kind of a hurry, you may as well call / visit your local dealer ... AFTER you have priced the parts online.  If the dealer has them in stock (a long shot, I know ) you could save a bunch of time.  Even if you have to order the parts, you might actually save money -- they usually don't charge you for shipping.

[BaoQingTian]

Here's some pics:

Here's the back of the bike.  I'm worried about the frame...it seems to be bent.  Is that a problem?


The chain sheared off the tips of the bolts and gouged the sprocket as well.


Below is what appears to be the culprit.  I would guess the chain was too loose, and bound up when I was taking that turn under hard acceleration.  This caused a link to break halfway at the rear sprocket and for the chain to come off the rear sprocket.  If anyone has any different ideas, please let me know.


I believe that this is the clutch pushrod that Markus was talking about


Does everything look normal here?  Or do I need to disassemble it futher to check inside?


Any help would be appreciated.  Oh, one more thing.  I can't seem to get the chain off the inner sprocket.  I know that there's a chain breaker- is it small enough that it could work in that tight of a space?  Or is there a way to get that sprocket off?  Thanks for your help all.  I guess I need to order another Clymer since it appears that I can fix this problem after all.

[hmmmnz]

wow you were lucky that didnt destroy the whole casing,
good luck:D

[Kerry]

The only thing keeping the sprocket in place (besides the chain) is the circlip on the end of the countershaft -- the "toothed" shaft that the sprocket is mounted on.

To remove the circlip you would ideally use a set of snap ring pliers to spread the two holes apart.  Folks have come up with various no-cost solutions as well.

Once the circlip pops off, you should be able to pull / wiggle the sprocket off the countershaft.  Of course, the chain will need to move horizontally along with it....

[GeeP]

Ow Ow Ow!  Lucky you weren't on the interstate when that happened!

Either the chain was running very loose, or it seized due to a lack of lubricant or sand infiltration.

Replace your sprockets, clutch pushrod, and the damaged hardware.  Disassemble the clutch cam inside the cover.  Clean and lubricate it before reassembly.  Clean everything else while you're at it, and inspect closely for damage.  Check the gear shift rod boss for cracks and check that the rod is true.  Check for hidden damage in the chainpath as well.

[aplitz]

Ouch, that doesn't look fun.  If you would like a hand fixing that, let me know, I'd love to help.  I wrenched on my GS quite a bit before selling it.

[Jace009gs]

Looks like your shifter rod is toast too:(...or that's a grese ball over the bearing.. in the one picture.


I would dissassemble the swing arm and  make sure it didn't get twisted while the rear tire was off.

Before any re-assembly tho I would check and recheck all the bearings' free play. If they are out of round that part that spins there is bad too...

Good news tho is that the clutch is is A ok once you get that pushrod replaced. When that rod snapped the clutch cable goes completly slack and the clutch is locked into engaged

[Blueknyt]

clutch pushrod is done, use a hammer and punch to pop the buched up chain section towards the front of the bike, the shifter shaft is going to be bend and perhaps some cracks around that area in the cases, but you will need the chain off and sprocket removed to loook closely. you might be ok with the shifter shaft but eather way the clutch cover must come off and clutch pressure plate removed so you can push the rest of the broken clutch rod out from the other side its about 5" long total and you had about 3 in your hand. if the shifter shaft IS toast then removing the clutch basket is the next item inline to get the shaft out.

[MarkusN]

The clutch actuator cam looks OK. Cleaning and checking it won't hurt, though.

You should be able to grab the remainder of the clutch pushrod with pliers and pull it out from the sprocket side. You see it in the third picture right in front of the sprocket.

If you were lucky and the shifter shaft was not bent you might get away without any more motor disassembly (apart from taking off the sprocket.)

Take a very close look at that swingarm. If it's bent or twisted get an used one to replace it. (They are plentyful on eBay.de. Dunno about the States.)

As for the sprocket bolts: grind or file the top of bolts and nut flat; you should then be able to disassemble.

Looking at how that chain got jammed in there I'm concerned for the sprocket shaft and its bearing as well. Be sure to observe this region for strange noises and the sprocket shaft for true running.

[RVertigo]

You are one lucky MF'er...  Your chain looks like shaZam! and it had to have been pretty loose to do that!!

LUCKY LUCKY you were seriously screwed up by that!!

[BaoQingTian]

Sorry, I'm brand new to wrenching on bikes.  I've turned my house upside down for the Clymer manual and can't find it.  I don't know what the shifter rod is.  I also don't know what the swingarm is or clutch actuator cam.  I assume the shifter rod is what my foot presses to change gears when the clutch is engaged.  The swingarm I don't have a clue.  Could someone point those out to me?   I don't mind replacing stuff that might be broken.  An extra 20 bucks is no big deal.

[Kasumi]

The swingarm is the section of the frame which holds the rear wheel. It moves up and down and is held in place by a large bolt like a rear axel bolt. The swingarm is attached to your rear shock. Its all about rear suspension. The shifter rod is what you change gear with - yea. I think your best bet would be to find someone on here or a few of them who could come over to your place and help you get it sorted. Im sure there's loads of people willing to strip down a GS