Desc is below
I had to replace my motor. I have tried to adjust both clutch adjustments all the way in and out. Replaced the clutch plates with the ones from my old motor and verified the oil level. With the lever completely out in first the engine does not die, and the rear wheel barely spins when given any throttle. Thoughts? I've checked everything I can think of at this point. Thanks :)
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Are you sure that it is not a gearbox problem, not actually selecting gear.
"Replacement engine and replace the clutch plates and still no drive sounds like it may not be in gear".
Macka
Prmas may be right... It may not have a gear selected. When on the centrestand, and in neutral, the rear wheel will rotate slowly with the motor running (they all do that sir).
Try selecting other gears with a firm hand/foot. Have the clutch cable adjusted so you have plenty of freeplay at the lever, say 3mm.
So you bought a second-hand engine??? I don't suppose you actually saw it running before you handed over the cash. :D
Given you have been working on the clutch I think firstly you need to go back and revisit what you have done and make sure everything is ok.
If you are sure the clutch is ok you could try this....
Get the bike on the centre stand, get a block of wood through the rear wheel to lock it against the swingarm. Take both sparkplugs out, remove the cover over the ignition advancer, get a spanner on the bolt head and try and turn the engine over. Do this with each of the gears selected. If it locks up in each one, great! If it doesn't there is a problem somewhere in the drivetrain.
This is a very long shot but.........The early GS5s were prone to wearing the spines off the gearbox output shaft. Suzuki overcame the problem by modifying the sprocket thickness and increasing the length of spline engagement in the later models. Maybe you should take a look at yours but you would probably hear it If it was slipping.
The wheel won't spin when in first when off, as it should. It clicks into first no problem, 2,3,4 the same. I was reading another post last night...could it be the pushrod or pushrod adjustment? If so, Anyone have links to a tutorial for this bike?
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Quote from: sledge on August 09, 2018, 03:15:05 AM
So you bought a second-hand engine??? I don't suppose you actually saw it running before you handed over the cash. :D
Given you have been working on the clutch I think firstly you need to go back and revisit what you have done and make sure everything is ok.
If you are sure the clutch is ok you could try this....
Get the bike on the centre stand, get a block of wood through the rear wheel to lock it against the swingarm. Take both sparkplugs out, remove the cover over the ignition advancer, get a spanner on the bolt head and try and turn the engine over. Do this with each of the gears selected. If it locks up in each one, great! If it doesn't there is a problem somewhere in the drivetrain.
This is a very long shot but.........The early GS5s were prone to wearing the spines off the gearbox output shaft. Suzuki overcame the problem by modifying the sprocket thickness and increasing the length of spline engagement in the later models. Maybe you should take a look at yours but you would probably hear it If it was slipping.
Running..kinda..? He hooked it up to a battery to show me it had compression. It was THE ONLY ONE I could find for a reasonable price. I drove 7hrs to TX to pick it up.$400
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The engine does not die when you let go of the clutch lever when in gear, but at the same time the wheel won't move when off and in gear? Is that right? Maybe it is the pushrod adjustment that's off. Might give the clutch pack enough friction to make the wheel hard to move by hand but not enough to kill the engine when running. Did you play around with that adjustment at all? There's a really good description of how to do it on this forum. Search for "clutch cable adjustment".
That's spot on. It will spin with a little bit of throttle like it is either just in or almost out of the friction zone.
Quote from: Drzon on August 09, 2018, 07:27:46 AM
The engine does not die when you let go of the clutch lever when in gear, but at the same time the wheel won't move when off and in gear? Is that right? Maybe it is the pushrod adjustment that's off. Might give the clutch pack enough friction to make the wheel hard to move by hand but not enough to kill the engine when running. Did you play around with that adjustment at all? There's a really good description of how to do it on this forum. Search for "clutch cable adjustment".
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Quote from: BondAddict on August 09, 2018, 07:29:52 AM
That's spot on. It will spin with a little bit of throttle like it is either just in or almost out of the friction zone.Quote from: Drzon on August 09, 2018, 07:27:46 AM
The engine does not die when you let go of the clutch lever when in gear, but at the same time the wheel won't move when off and in gear? Is that right? Maybe it is the pushrod adjustment that's off. Might give the clutch pack enough friction to make the wheel hard to move by hand but not enough to kill the engine when running. Did you play around with that adjustment at all? There's a really good description of how to do it on this forum. Search for "clutch cable adjustment".
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So it spins, but very very slowly at around 3-4k rpm
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Perhaps you should buy a service manual :dunno_black:
Quote from: sledge on August 09, 2018, 10:16:24 AM
Perhaps you should buy a service manual :dunno_black:
I have one. A oem pdf manual. I didn't see anything about the pushrod though.
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If I need to replace the pushrod...how does one removed the inner and outer one? Just pull?
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Before you replace anything, have you tried adjusting the nut that controls how much the clutch cable actually pushes / pulls against that rod?
Quote from: Drzon on August 09, 2018, 10:34:56 AM
Before you replace anything, have you tried adjusting the nut that controls how much the clutch cable actually pushes / pulls against that rod?
The one that on the cable going into the transmission? Yes, I tried adjusting that in and out.
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I'm talking about the clutch mechanism adjustment screw, I believe. Look through the thread pasted below and check if you adjusted in all the mentioned areas.
http://gstwins.com/gsboard/index.php?topic=20468.0
Quote from: BondAddict on August 09, 2018, 10:18:26 AM
Quote from: sledge on August 09, 2018, 10:16:24 AM
Perhaps you should buy a service manual :dunno_black:
I have one. A oem pdf manual. I didn't see anything about the pushrod though.
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In my copy.....
Section 2-11 covers clutch adjustment
Section 3-40 covers clutch inspection, plates, discs, springs etc