GS500 Clutch Problems

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foxracer06 · Fri Mar 20, 2009 7:06 pm

so ive got a 2006 Suzuki GS500F, just hit 24,000 miles on it, i was having problems with the clutch slipping at about 18k, bought new springs and fiber plates and installed them, seemed to work fine for a day or two but started slipping promptly, weird thing is when the bike is warmed and about 25miles of driving it works fine....but every morning i start it up it slips when i hit the throttle hard untill i ride it for about a half hour or so....so i got fed up again and ordered new fiber plates, steel plates, and springs, and installed them thinking the new steel plates would help, i also installed new o-ring chain and -1 tooth front sprocket and new stock rear sprocket, took it down the street for a spin and got it topped out 110 mph quickly no problems, i then adjusted the clutch play a little bit and then took it on a 25 mile ride into town, had dinner for about an hour, then when i got back on the bike let it warm up for 5 min or so and took it out to the free way the clutch started slipping just as bad as ever....im frustrated as hell right now does anyone have some suggestions? ive had this bike for 22,000 of its 24,000 miles and i know how to take it apart and put it back together in a day but cant seem to fix this problem and no mechanic i ask can give me any hints? im hopeing someone has had the same problem.....any input is welcome thank you

#2 Unread post by **Wrider** » Fri Mar 20, 2009 7:32 pm

Hey there... Did you soak the fiber plates in oil before you installed them? And are you sure you put all of the steel plates in facing the same way? I've seen where highly experienced mechanics didn't get the steel plates in the right way and it makes the clutch slip like that.
Also have you replaced your pressure plate in the very back of the clutch basket? If not I'll put money on it that it's worn out.
Oh, and just to make sure, you are using motorcycle specific oil right?

foxracer06 · Sat Mar 21, 2009 1:52 am

so doing as much research online before i did the clutch yesterday i did soak the plates in 10w-40 for about 30 min, i did install all the metal plates with flat side facing in, didint replace the pressure plate so i might have to try that next, just hope i dont ruin the plates before suzuki sends me the new part in a month lol, also if it calls for 10w-40 and i use castrol synth blend for motorcycles that should be ok? i could not find anything saying that could hurt the bike

gsJack · #4 Unread post by **gsJack** » Sat Mar 21, 2009 3:06 am

Have you adjusted the clutch in all 3 places? There's a screw and locknut under the little cover on the sprocket/clutch lever cover on the left side where the clutch cable goes in that can cause slippage if there is no push rod free play. It was the cause reported by a few of our gstwin board members.

I had too much freeplay there on my 97 GS and clutch action was erratic until I discovered and made that adjustment. I put 80k miles on that bike and my son ran it up to 88k miles before he put in a late model low milage used engine due to high oil consumption, all on the original clutch. I have 67k miles on my 02 GS now on the original clutch and like the 97 I find little clutch adjustment is required on the GSs in all those miles once it is setup right unless you are particularly hard on clutches.

Ask over at gstwins if you don't get the problem solved, it's a very active board:

http://www.gstwins.com/gsboard/

foxracer06 · Sat Mar 21, 2009 3:18 am

thanks for the replys i will try to adjust the pushrod out a lil further when i adjusted it yesterday i had it pushed in alot and then loosed the adjustment on the lever...might just have to play around with it....im just wondering why the clutch slips when started in the morning but when fully warmed up it works fine? any thoughts?

gsJack · #6 Unread post by **gsJack** » Sat Mar 21, 2009 4:10 am

You need to screw the clutch cable into the engine cover until there is way too much freeplay and then adjust the push rod clearance first to provide a little clearance at that point. Back off the screw until it is free of the pushrod and then turn it in until it just touches and then back it off 1/4 turn and lock it to give proper rod freeplay. Next screw the adjustment at the clutch lever in all the way and and lock it and then make the final adjustment where the cable goes into the engine cover to give proper clutch lever freeplay. You can make future adjustments by hand at the lever after that to compensate for wear if required.

Your probably just on the edge of slippage now and temp changes cause it to slip or not as you warm up. Get it all set up right first and see how it works out.

#7 Unread post by **Wrider** » Sat Mar 21, 2009 5:30 am

You said you soaked them for 30 min. That could very well be the problem, the factory recommended minimum is an hour, and the recommended time is 24 hours. So make the adjustments GSJack was talking about and if you still have a problem soak your next set for a whole day before install...

foxracer06 · Sat Mar 21, 2009 7:35 am

hey thanks for the input guys its my first time using this site and you helped alot

so on my lunch hour i opened up the pushrod cover, i had not opened it since i had to replace the pushrod due to it snaping on me on a 100 mile ride (worst riding experience ever riding home with no clutch at all)

it turns out the set screw was stripped out a bit and had moved in alot closer than i remember setting it about a year ago, since i work at Home Depot i cut a piece of all-thread to the correct length and a new nut and set it the way you desciribed, with the motor cold i started it up and adjusted the clutch play, tested it a bit and took it for a ride and it seems to be working fine, monday i will order the correct suziki parts but my local bike shop has been having trouble getting suzuki parts in a timely mater (my clutch parts and shift linkage took almost a month) so i think my quick fix should last that long

on another note this bike has been a two year project of mine, any other mods you can think of for some more pep?

ive got this so far, Jardine header, Two brothers gsxr slip on muffler, ngk irridium plugs, kn filter, -1tooth front sprocket, stock rear sprocket. i know i need to re jet the carbs but ive only ever played around with V8 truck carbs would it be much harder of a task for my skill?

also i just hit 24k miles and it runs awesome what are your thoughts on valve adjusting and how hard is it? ive read some posts on gstwin but not sure if my time is worth they price the shop charges

#9 Unread post by **Wrider** » Sat Mar 21, 2009 10:02 am

Honestly as far as practical mods on a GS you're about as far as you can go. I mean obviously you can put on an oil cooler, a turbo, big-bore, NOS but then you'll be about equal with a 600 in terms of power for a lot more money!

For just a bit more pep I'd suggest putting cone filters on the carbs instead of your stock airbox, then adjusting your carbs to match (it'll run a whole lot leaner once you put those on). If you really want to go berserk I'd toss in some performance cams!

Carbs are easy on bikes, single barrel per cylinder, and on the GS they're easy to get off and get back on, especially since you have mechanical experience.

Valve adjusts, I'm not gonna lie, getting the bucket depressor in there is a PITA, takes just the right feel, but after you do that it's pretty easy as they have a shim-over-bucket design, eliminating the need to remove cams and re-time the cams and all that.

Glad you figured out your problem! Sounds like you got it under control!