GStwin.com GS500 Message Forum

My clutch seems to be very stiff and I have to pull it very hard to ingage. I was checking the cable and if I disconnect its moving freely so it has to be something else. Can any one please help ?

Check that the lever pivot bolt isn't too tight. Is it well greased? Or, is the clutch actuating pivot (the verticle part in the gear cover) well greased? I kinda doubt it's the clutch rod, but maybe the tip where it meets the actuating pivot needs to be greased? Lastly, I would suspect stiffer aftermarket clutch springs.

Is this your first bike? If so, you may just need to get used to it and/or pump up (work out) your forearm strength.

Hope this helps.

Clearly you have never owned a Moto Guzzi.  :lol:

Quote from: gerharddvsMy clutch seems to be very stiff... if I disconnect its moving freely so it has to be something else.

Where did you disconnect it? At the handle or the clutch lifter on the left engine side?

Quote from: starwalt

Quote from: gerharddvsMy clutch seems to be very stiff... if I disconnect its moving freely so it has to be something else.

Where did you disconnect it? At the handle or the clutch lifter on the left engine side?

I removed the engine cover so it could move freely

My previous bike was a Suzuki A100 (100cc), quote a dinkytoy. So maybe I should just get use to it.
I did find on removing the cover on the setting screw on the shaft that the ballbearing between the screw and the shaft was missing and I found it in the casing (previous owner must have slipt up). After putting it in again the clutch feels a bit lighter but I just don’t want it to fail me in a couple of miles.
I also ound another problem. The gear shaft seal is leaking so I'll have to replace it

Ahh!  You can look at my clean up job here (http://home.bellsouth.net/p/PWP-starwalt) of the same cover. It could be that several of the ball bearings are missing OR the lubricant should be replaced. It was amazing how easy mine moved with no lubricant and only the bearings. The original lubricant was very stiff and resistive.

With a smooth moving clutch lifter, only the clutch springs will offer resistance.

Ok Gerhard, here's the photos of the clutch lifter mechanism. The first is the inside of the housing without the lifter arm. This is the inside of the cover looking outside. The brass end of the lifter arm is inserted here.
(http://216.77.188.54/coDataImages/p/Groups/41/41309/folders/179572/1415917Clutchlift1.jpg)
There are 11 ball bearings inside the sleeve. There are 4 spirals on the lifter mechansim. Each spiral gets 3 balls except one. It has only 2. Here's a cleaned up lifter arm.
(http://216.77.188.54/coDataImages/p/Groups/41/41309/folders/179572/1415919Clutchlift2.jpg)
The brass end on the right lower side is the adjustment accessed from outside the cover. The spiral section and sleeve should be packed with grease to prevent wear and aid in movement.

If you need more information, let me know.

what exactly is adjusted through that cover?

Thanks for the pics. It seems I have another problem then. I didn't know you can remove the whole shaft and gear assembly let alone grease it.
If I was finding loose balls in the casing it means those bearings are worn out. Are they suppose to be in the shell or are they lose ?
It also means I have put the lose bearings in the wrong place. I sow on another bike that they put a bearing between the that brass setting screw on the end, and the push shaft, so I put it there. Also I didn't grease the gear I just put some oil. Suzuki doesn't sell that bearing lose they just sel the whole assembly and they want a hel of a price for it to.
Is there suppose to be a bearing there or have I screwd up big time ?
Another thing thats bugging me. My shaft is in 2 peaces, one on the engine side and one on the sidecover side. Is it suppose to be in 2 peaces ?
Please help ?

PS Dispite everything the clutch seems a bit lighter know and a shifting problem I had on the gears has vanished, maybe the shaft they had in there is to short could you maybe measure yours[/img]

Quote from: se7enty7what exactly is adjusted through that cover?

The clutch

Quote from: gerharddvsIf I was finding loose balls in the casing it means those bearings are worn out. Are they suppose to be in the shell or are they lose ?

If I remember correctly, they can fall out. In my pic, the old grease is sticky enough to hold them in. The shell holds their position constant. Compare the loose ball to these. In the drawing below, the shell and mechanism are considered a single replaceable unit.

QuoteIs there suppose to be a bearing there or have I screwd up big time ?

As you will see, the bearing does not go there.

QuoteAnother thing thats bugging me. My shaft is in 2 peaces, one on the engine side and one on the sidecover side. Is it suppose to be in 2 peaces ?

Yes, the the Clymer drawing shows a left and right pushrod.

QuotePS Dispite everything the clutch seems a bit lighter know and a shifting problem I had on the gears has vanished, maybe the shaft they had in there is to short could you maybe measure yours

If you put the loose bearing inside the spiral arm, you lengthend the pushrod. Here's a highlighted scan of the area we are discussing.

No ball bearing on the shaft end shown in this breakdown. I suspect Item 25 should be adjusted instead to increase or decrease the throw of the pushrod. The cover would be to the right of the parts line.

Hope this helps!

I was disassembling and cleaning everything this afternoon and found that including those lose balls, all 11 of them are accounted for. I'm going to see if I can't find new ones tommorow since these look a bit warn out (maybe at a bearing shop).I'll then pack everything with grease and assemble. I also replaced the geashaft seal.

I see I've got a bit of play on the front sprocket, not in the chains direction but moving allong the splines. Should I worry about it cause I could try and find a thicker washer to put under the clib.

Thanks for all the help. I know Ive been bugging you allot but it's my first bike and I don't want to muck her up and if the previas owner did I'd like to find the problems and fix them asp.

QuoteThanks for all the help. I know Ive been bugging you allot but it's my first bike and I don't want to muck her up and if the previas owner did I'd like to find the problems and fix them asp.

Not a problem Gerhard! When you get your manual, many things wil be clear to you. I have both the Clymer and Haynes manuals. In my opionion, the Clymer has a slight edge over the Haynes when it comes to technical information. On the other hand, the Haynes is very enjoyable and informative about the GS and gives many tips on self service. The Haynes has information the Clymer does not. The converse is also true. Obtain them both if you can.

Soon I will be "bumping" my project post with more pics and words.

Quote from: starwaltI have both the Clymer and Haynes manuals. In my opionion, the Clymer has a slight edge over the Haynes when it comes to technical information. On the other hand, the Haynes is very enjoyable and informative about the GS and gives many tips on self service. The Haynes has information the Clymer does not. The converse is also true. Obtain them both if you can.

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Ahhhh.  Vindicated!  I concur.  :thumb:

starwalt - would you agree that the Haynes is the "better" manual for folks that want to do most of their own maintenance but don't want to mess with splitting engine cases, opening up clutches, etc?  (In other words, the majority of folks on this board?)  It's just so much easier to find things, and Chapter 0 is priceless.

If anyone wants a walk-through example & comparison, see the Paging Mr. Clymer!... thread.
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Quotestarwalt - would you agree that the Haynes is the "better" manual for folks that want to do most of their own maintenance but don't want to mess with splitting engine cases, opening up clutches, etc? (In other words, the majority of folks on this board?) It's just so much easier to find things, and Chapter 0 is priceless.

Kerry, this is like asking which beautiful woman of two beautiful women is more beautiful? I feel like the young mortal dealing with the goddesses.  :lol:

Haynes is more engaging to the casual reader and seems to be easier to look at. The "user interface" is better, and the little tips that make a job easier are integrated into a particular process. It is more like working with your grandpa on a project. He would tell you where you should and should not put your fingers. He would also show you how to use a belt buckle to build a starship plasma drive regulator (Ok. I made that up.).

Clymer, though no less technically correct, is more akin to the grandmother who would say, "I explained that to you before. Don't you remember?" before walking away leaving you pondering. "Oh, and don't forget to eat your brusslesprouts also!"  :?

Metaphorical analogies to be true. Neither can take the place of what Gerhard is experiencing by getting his hand into the machine. Let us hope his ordered book arrives soon.

I concur with all of THAT too.  Well put!  :)