My 2001 GS just started making some weird sounds today and I'm not sure what it might be. I changed the tires last week and put it all back together and it has been riding just fine, until today. Coasting to a stop with the clutch  pulled in, I shifted from maybe 4th down to 1st and braked to a stop. As I slowed down I heard a rubbing noise getting louder and louder, and felt some pressure in the clutch handle. It kind of startled me, so I let out on the clutch just slightly (enough that usually the RPM would drop a bit) and the bike immediately stalled. Started back up and had a lot of lugging/jerking while getting up to speed, but once I shifted out of first it was perfectly fine.

I rode the rest of the way home, engine braking gear by gear and didn't have the issue again. When I made it home, I tried to recreate the issue by doing a similar stop (riding in 3rd, clutch in, downshift to 1st and use brakes to stop) and the same thing happened. What should be the first things that I check here? Oil level is fine and the chain has about 1 inch of play when on the side stand.

might be far fetched, but take you clutch cover off and look for notching in the clutch basket.

I just took off the sprocket cover and found this. Looks like the chain is rubbing on the little lever above the spring. THe outside of the chain has fresh wear marks on it too. Any ideas how to stop that?


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did the circlip fall off your countershaft?

No, it is still there where it belongs

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I replaced the circlip with fresh one just to be sure, I'll see how that works after I get my carbs back togther. Thanks

Did you remove the sprocket when you changed tyres?
Are the chain/ sprockets alignment and the wheel alignments ok?

Interesting. When you actuate the clutch, it does move that towards the sprocket. Is the clutch actuation too much, the adjustment on the outside under the plate? 

Replaced the circlip with a new one, rechecked alignment, and adjusted the clutch cable slightly. I didn't have the issue on my short ride to work today, so hopefully it is taken care of

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Now boys, we need to figure this one out.
Could it be the clutch pushrod has worn a little too short, resulting in the release lever sitting further in towards the sprocket, causing the lever to graunch on the sprocket.
?

I've not experienced any wear problems in the clutch actuating parts in 80k miles on my 07 and now over 100k miles on my 02.  I'd start with a proper 3 point clutch adjustment as described in the shop manual to make sure clutch is set up properly and the actuating lever is no extending out too far from the housing.

http://img.photobucket.com/albums/v443/jcp8832/GS500clutchadjustment_zps58ca4ce8.jpg

This makes sure the cable is totally relaxed when the push rod free play is adjusted so lever will be fully retracted when at rest and will not go out further than intended when fully actuated.  I did replace the clutch cable on both of my GSs at 50-60k miles, the clutch cable on my 02 CB750k wore and broke every 30k miles.