WTF Bike turns on revs up doesn't move in any gear, 82 GS450

[BiellaBound]

How you doing forum,

Please don't go too hard on my overall stupidity.

The issue all starts with changing the handle bars and over torqued the bolt at the clutch side perch (stupid move 1).

I bought and installed a Shorty Clutch perch and Lever, and had to shirt the Clutch Switch since there wasn't an area for it on the new Lever.

Took the bike for a really short ride to test the new bar ends and it all worked fine the bypass and all.

stupidity 2 - pulled in the driveway and had to leave fast, turned the bike off by kill switch and left the key in on the on position......battery completely drained, so I just installed a new one yesterday and it fired up, put it into first and eased the clutch, nothing. Engine revs, idiot light shows gears and it was shifting with out the clutch to first and up to 2nd...didn't go much higher.

The lever was stiff (was that way with original perch and lever) but the longer lever made it tolerable. I went to loosen the bolt at the clutch case and keep letting it out and the stiffness didn't change, at some point the bolt split and was sitting loose.

I am freaking out on what the issue is, clutch cable broke or frayed? Not full engaging? Or clutch plate issues.

I not super mechanical with bikes, put a somewhat quick learn. I didn't want to take the clutch cover off yet and have to drain
the oil in the event I can push start it in second (saw some videos that could get me to my mechanic if need be 1 mile ride and no friends with pickups)

When I got the bike it ran fine, needed a little tuning, but with those drag turn outs there not much they could do, first bike took it to a shop and swept the floors to shadow and learn more about maintenance.
First pickup

And now

I am relatively new to the forum, lurked for months before getting my first bike.




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[alzcbz]

Sounds like clutch is not adjusted properly. It's likely you don't have any free play at the clutch lever. Do you have a manual so that you could follow the correct procedures for your model?


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[BiellaBound]

Sounds like clutch is not adjusted properly. It's likely you don't have any free play at the clutch lever. Do you have a manual so that you could follow the correct procedures for your model?


I have a manual I online, my issue I think is the broken bolt at the adjuster, nor are what to do there

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[Tune-A-Fish]

If I remember right... You have an inspection cover you can remove (2 screws) and get the cable loose at the case, then pull the case to remove the broken part... put a new cable on and adjust correctly. If the clutch adjusts out as far as you have it the thing is at the end of it's useful life and you need to look at a new clutch stack.

It looks as though you were tightening rather than adding slack.

 

[BiellaBound]

I am thinking that as well, thanks for the fast response. So drain oil remove clutch cover, remove cable and try to get the broken screw out....hopefully there is enough left in there to get a grip on and then replace clutch cable? Seems to be what you are referring to


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[barnett468]

.
ok, is, or was, there any freeplay in the clutch lever?

 

[Tune-A-Fish]

I am thinking that as well, thanks for the fast response. So drain oil remove clutch cover, remove cable and try to get the broken screw out....hopefully there is enough left in there to get a grip on and then replace clutch cable? Seems to be what you are referring to


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Not going to be much but yeah you may be able to grab just enough with something and turn it out... if not cut the cable and use an easy out or snug fit drill bit and run it down and out. I don't remember but I think that is not the "clutch cover" side, the clutch is opposite and a rod runs through to actuate the pressure plate throw.

 

[BiellaBound]

.
ok, is, or was, there any freeplay in the clutch lever?

lever moves but is stiff could be just an old cable


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[BiellaBound]

lever moves but is stiff could be just an old cable


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thanks for the info, contemplating just taking it to the mechanic, I take a step forward and two back


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[datadavid]

Yes, sometimes its good to know your limitations.. but how are you gonna learn anything if you dont make mistakes!?
Man all the stuff i broke through the years are my best teachers!

 

[BiellaBound]

Yes, sometimes its good to know your limitations.. but how are you gonna learn anything if you dont make mistakes!?
Man all the stuff i broke through the years are my best teachers!

I hear you, might take a shot at it myself/ YouTube. For sure everything I know in life pretty much was learned from a mistake


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[barnett468]

lever moves but is stiff could be just an old cable

if you tighten the lever pivot bolt too much, the lever will not move freely . . make sure the lever moves freely without the cable.

 

[BiellaBound]

if you tighten the lever pivot bolt too much, the lever will not move freely . . make sure the lever moves freely without the cable.

Thanks, good point. Lever moves very freely without cable


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