gt380 stuck in neutral ... Help!

[kayakboy]

I have done a lot of work on this 75 gt380 off and on over the past year and I'm getting close to getting it running. I was not
running when I got the bike. The clutch cable was broken at the time and I've since replaced It , and I have adjusted the clutch by the manual. The clutch seems to be engaging (I think). The shift leave will not go up on down with or without the clutch engaged. Before I restored the bike you could shift the gears , even without the clutch cable attached.
Any help from you Pro's would be greatly appreciated . Please don't give me the bad news of having to split the Case .
Thanks Folks!!

[Suzukidave]

My first guess would be the shifter pawl behind the clutch cover is not engaged with the shift drum properly .

[titan performance]

Might be worth having a look at the clutch......plates may be stuck together.

[kayakboy]

Suzuki Dave, I think you were right! The Gear shifting pawls 1 & 2 seem to be out of their slot. The next question is.. How do I get them back in the proper position?? I Thanks again for your help.

[Suzukidave]

Without the shifter lever mounted on the shifter shaft , the shaft will pull out from the clutch side hopefully enough for you to re engage the pawl correctly . I dont have a 380 picture but this one from a GT750 should look very close when lined up correctly .. make sure the spring behind the pawl is mounted so half is on each side of the post , you can see the return spring through the window in the pawl

[Coyote]

Looks exactly the same on a 550. By the way, in the photo that Dave provided, the bike is in neutral.

[kayakboy]

Thanks Dave for the photo. I followed your instructions and I now have the shift arm in the position in your photo. I also split the spring between the shifting arm stopper... the spring had both arms on the bottom of the stopper , this I think caused the problem. Moving the spring in the proper position I have a lot of play in the shifter . In the Manual the view shows the spring ends are as wide apart as my gt380. The spring is not tight to the stopper as your photo shows on the gt750. So, I assume
that this is good and I can put this this thing back together? I would of posted a photo, but I was unable to find a way to do
that on this site.
With all the clutch components out I found the "Clutch Sleeve Hub" with several stress cracks in it. I may have to forgo assembly for now until I find one .
Thanks Dave for your help.

[Suzukidave]

Good deal any of the Suzuki models the spring behind the pawl should be tight on the post as shown as its the centering spring .. it returns the pawl and shift lever to the middle between shifts .

[kayakboy]

Since my spring is not tight to the post ... does this mean I need to remove and or replace it? The manual view shows the same spring as I have , the ends are flared and there is a wide space between the ends that go around the post. The ends not being tight around the
post , gives the shifter a lot of play.
What is your thought on replacing the cracked Clutch Sleeve Hub? I guess it's a no brained ... it I can find one!
Thanks for your help!

[Suzukidave]

As far as i know the spring should be tight to the post . If the 380 shift pawl is like the 750 it also has a post mounted to the back side , the spring can be pre set to the pawl before its slide into place and there it also fits over the post mounted to the case .

[Suzukidave]

I dont know how much the clutch sleeve is at the dealer .. if you can still get it , but ebay looks to have lots of clutch parts http://www.ebay.com/sch/i.html?_from=R4 ... t&_sacat=0" onclick="window.open(this.href);return false;

[kayakboy]

Hey Suzuki Dave, I still have a few questions on the pawl gear. One being ... my pawl gear is now in the right position ,by your photo, but does not stay in place with the shifter on. It seems to work fine as long as I hold the pawl in.
I also have concerns about the spring.. I have it on both sides of the post but it doesn't seem to do anything!
I have a photobucket account now and I wanted to attach a photo for your review, However, I'm not the best with computers!

[Suzukidave]

Hey guys .. anyone have a shifter out of the case handy that you could display the proper spring placement ?

[yeadon_m]

http://s280.photobucket.com/user/yeadon ... ml?filters" onclick="window.open(this.href);return false;[user]=73924161&filters[recent]=1&sort=1&o=0

http://s280.photobucket.com/user/yeadon ... ml?filters" onclick="window.open(this.href);return false;[user]=73924161&filters[recent]=1&sort=1&o=1

The shifter sits 'inside' that return spring so that, when pressed up or down, it tensions the spring, and acts to return it to centre when released.

The whole shaft will slide out of engagement with the pawl, if pushed rightwards, when the clutch cover is missing. Easy to do if you slide the shift lever on, but its OK, it cannot do this when that cover is on, because the end of the shaft butts up hard to the inside of the cover.

Cheers,
Mike

[yeadon_m]

http://s280.photobucket.com/user/yeadon ... ml?filters" onclick="window.open(this.href);return false;[user]=73924161&filters[recent]=1&sort=1&o=0

http://s280.photobucket.com/user/yeadon ... ml?filters" onclick="window.open(this.href);return false;[user]=73924161&filters[recent]=1&sort=1&o=1

Dunno why the links don't seem to work? the links pasted work fine before I posted them