Low Gear Problems (Clutch Slipping?)

[Gargoyle7]

Hi Guys,

My 2007 GS500 (36***km) has been having trouble in the lower gears lately. When in first or second gear, the engine revs extremely high with little acceleration (First Gear RPM around 5000 at 15-20km/hr). Thinking that the oil could be causing the clutch to slip, I recently changed it but it didn't solve the problem. I've been using 10W-40 regular motor oil (Not energy conserving).

Things to note:
-Can't get bike into 6th gear
-Sometimes hard to find neutral
-Bought from a training school at 33*** km
-Carburetor needs to be cleaned
-Heavy vibrations against left leg when accelerating above 5000rpm
-The problem is far worse with the choke open

My guess is I need to rebuild the clutch?
-If so will I most likely only need friction plates, gasket, and springs?
Could it be a clutch cable problem?

Its final exam season here so I won't have the time to rebuild the clutch for a few more weeks but I'd like to order in the parts.

Thanks,
Peter

[Watcher]

Since you said it came from a school I'd be looking into a new clutch set, those kids are not easy on the bikes.

That being said, you can try a 3-point clutch adjustment first to see if it helps at all.

[Big Rich]

Try adjusting the cable as Watcher suggested. If that doesn't work (it probably will), the clutch is pretty easy to rebuild. But.... "but" let us know if it does as there are a few things worth mentioning. 

The heavy vibration above 5k rpm...... might want to get your carbs balanced after they get cleaned. Have you checked the valve clearances yet? That needs done before you can sync the carbs.

[Gargoyle7]

Okay thanks guys! I had a go at adjusting the clutch again and I noticed that the pushrod screw is all the way in with the lock nut stuck at the very end of it. The threads where the locknut is are damaged and I am unable to tighten it or back it off the screw. I can, however, remove the screw entirely.

I won't be able to touch the carbs until the end of April but I'll be sure to check those out.

[Gargoyle7]

Okay so I replaced the pushrod adjuster screw and nut.
It looks like I've completely run out of cable adjustment. Lever adjuster is all the way out, pushrod adjuster all the way in and the adjuster above the sprocket cover is all the way out.
Any ideas?

[Gargoyle7]

Okay so I replaced the cable and still no luck, everything maxes it out and there is still no tension in the lever. Should I start opening the clutch up?

[Big Rich]

There's zero tension on the cable? If so, that's very strange.....

It might be a good idea to open up the clutch. You'll want to order a new gasket for the clutch cover (almost always rips taking the cover off). If you don't plan on riding for a while, I would just open it up and inspect everything. But if you're anxious to ride and have the cash, start ordering parts. Use whatever clutch plates you want (you don't need "racing" parts....), and I recommend OEM clutch springs. The plates need soaked in motorcycle oil before installing. And watch the order of the metal / fiber plates when taking the old one apart.

[Gargoyle7]

Okay thanks man, I'm actually going to go open it up right now and have a look.

In regard to clutch plates, are motorcycle friction plates more or less universal or do they have to be vehicle specific? I'm in Canada so the selection is a lot smaller.

[Big Rich]

Not so universal, but I think the GS shares plates with other Suzuki bikes. Have a look on partzilla:

http://www.partzilla.com/parts/detail/suzuki/SP-21441-37400.html

These are all the bikes that use the same plate (but maybe a different number of them fyi). But anyway, you'll want to buy a set made for the GS500. A Suzuki dealer "might" have what you need, but I would just order online personally. I'm in the US, so I have no idea where you could get them from - sorry.

[Gargoyle7]

SOLVED: A new clutch clutch kit cured all the issues.

[herennow]

 ;)2 year clutch change job  -  you work almost as fast as I do