Clutch is stuck engaged

[Kaden]

Help
 

Hey guys, picked up a 1995 gs1100r last year and rode across the country. I made it 100 miles from the end before I had issues. My clutch felt funny the night before and I forgot to check it. It felt like I had to pull it in farther in order to get it to disengage. I was later pulling off the freeway to fill up and when I pulled the clutch it came all the way in and never disengaged, luckily I made it to the gas satiation stick in fourth.

 

I limped it back and need to fix it. I read some forums and want some advice on where to start. The lever, cable, and arm are all working but somewhere internally it is not working. I opened the cable and pulled it farther and just heard a little grinding. It almost pops slightly when I pull it while in neutral. Does anyone have happy news of something easy? I am 2200 miles from home and only have tools that I brought. I am expecting to open up the bike.

 

Thanks

[dirtrider]

32 minutes ago, Kaden said:

Help
 

Hey guys, picked up a 1995 gs1100r last year and rode across the country. I made it 100 miles from the end before I had issues. My clutch felt funny the night before and I forgot to check it. It felt like I had to pull it in farther in order to get it to disengage. I was later pulling off the freeway to fill up and when I pulled the clutch it came all the way in and never disengaged, luckily I made it to the gas satiation stick in fourth.

 

I limped it back and need to fix it. I read some forums and want some advice on where to start. The lever, cable, and arm are all working but somewhere internally it is not working. I opened the cable and pulled it farther and just heard a little grinding. It almost pops slightly when I pull it while in neutral. Does anyone have happy news of something easy? I am 2200 miles from home and only have tools that I brought. I am expecting to open up the bike.

 

Thanks

Evening Kaden

 

That is going to difficult to diagnose over the internet without more info.

 

I have seen the trans lever crack then bend, I have seen the trans laver adjuster bolt back out, I have seen the release push rod wear through the clutch spring, I have seen the trans lever bearing wear & come apart. 

 

How much clutch hand lever free-play do you currently have? 

You might check the adjuster bolt in the trans lever to make sure that it hasn't worked loose & backed out.

 

See if you can access enough of the trans lever to see if it looks bent or broken?

 

Unless it has been updated your 1995 should have the early multi-piece thrust bearing.

 

[Kaden]

thank you 
 

The lever looks like it is in good condition, and the bolt has not backed out.

[dirtrider]

5 minutes ago, Kaden said:

thank you 
 

The lever looks like it is in good condition, and the bolt has not backed out.

Evening Kaden

 

If you reach in & move the trans lever how much fore/aft movement does it have? 

 

Does it have a lot of movement or just a little (like normal free-play)?

 

Does the handle bar clutch lever feel normal with the normal amount of spring tension or it limp with a lot of free play?

[Kaden]

It is completely limp. Feels like no tension. I tried to see if I could move the clutch lever farther with a jigged wrench but it won’t go anymore than the cable is already pulling it

[dirtrider]

18 minutes ago, Kaden said:

It is completely limp. Feels like no tension. I tried to see if I could move the clutch lever farther with a jigged wrench but it won’t go anymore than the cable is already pulling it

Evening Kaden

 

Well if the lever isn't bent, & the adjuster bolt hasn't backed out,  & the clutch cable is not broken, & the cable is properly attached to the hand lever, & the cable adjuster isn't stripped at the hand lever then your problem is most likely in the release bearing, or the push rod, or the pushrod to clutch diagram spring interface, or in the clutch itself (like the lining has come loose & jammed it up).  

 

 

[Kaden]

Sounds like fun! I guess if that’s all good I just open it up and look?

 

thanks

[dirtrider]

1 minute ago, Kaden said:

Sounds like fun! I guess if that’s all good I just open it up and look?

 

thanks

Evening Kaden

 

This is a tough call from afar with no hands on & even then it might take some digging to find the root of the issue. 

 

Even if you find the problem & if it is in the release bearing itself, then that might not be an easy fix if your motorcycle still has the early parts as that early release bearing parts are mostly not available any longer.   

 

I need to step away for the remainder of the night so if I don't respond tonight I'm not ignoring you, I will be back tomorrow morning.  

 

If you have more questions hopefully someone else on this board can chime in & help you. 

[Kaden]

I let it cool down and checked it again. The last third of pulling the lever had some tension for the first 10 seconds. While it had tension there was very loud squeaking. Eventually it popped and disengaged more again and the tension was gone. Only lasted about 10 seconds. Thanks.

[dirtrider]

11 hours ago, Kaden said:

I let it cool down and checked it again. The last third of pulling the lever had some tension for the first 10 seconds. While it had tension there was very loud squeaking. Eventually it popped and disengaged more again and the tension was gone. Only lasted about 10 seconds. Thanks.

Morning  Kaden

 

Was that "loud squeaking" on clutch lever pull with the engine running or with it off?

 

It's still difficult to tell you much without having the motorcycle in hand. 

 

It sort of sounds like the release bearing (piston), hopefully it isn't deeper than that. 

 

I have seen a couple where the front of the clutch push rod wears into the clutch diaphragm spring pocket. This usually causes a lack of clutch release but from what I have seen the clutch release doesn't come back as the push rod sticks in the diaphragm.

 

If your motorcycle still has the early release bearing there is a bushing on the push rod (not needed with the later release bearing) if that fails I'm not sure if that would cause what you are feeling or not. 

 

 

[Joe Frickin' Friday]

1 hour ago, dirtrider said:

It sort of sounds like the release bearing (piston), hopefully it isn't deeper than that. 

 

The throwout bearing can probably be inspected/replaced with a limited amount of hassle.  I was able to do this on @OoPEZoO's oilhead R1100RT in the parking lot at a BRR event many years ago.  I can't remember whether we removed the rear wheel, but I was able to reach in above the swingarm and take out the throwout bearing without having to remove the swingarm.  Googling pics of a '95 R1100GS, it looks like it has the same swingarm and gearbox housing, so it might be possible to this on the OP's bike.  

[dirtrider]

51 minutes ago, Joe Frickin' Friday said:

 

The throwout bearing can probably be inspected/replaced with a limited amount of hassle.  I was able to do this on @OoPEZoO's oilhead R1100RT in the parking lot at a BRR event many years ago.  I can't remember whether we removed the rear wheel, but I was able to reach in above the swingarm and take out the throwout bearing without having to remove the swingarm.  Googling pics of a '95 R1100GS, it looks like it has the same swingarm and gearbox housing, so it might be possible to this on the OP's bike.  

Morning Mitch

 

On the 1100 you can usually get to it (with a fair amount of lip biting & tooth gnashing) by removing the rear tire & removing the rear shock then moving the plastic wheel closeout. (if working with bike on center stand then be sure to strap center stand to front wheel or to front exhaust so it doesn't collapse & trap your arm in there)