1981 GS550L Stiff Clutch

[ProducerBill]

I have been rebuilding a 1981 barn find that sat for 35 years. It have been fun, but I am struggling with the Clutch. The clutch was extremely hard to pull. By extremely hard I mean nearly impossible. So I disassembled both the clutch basket side and the sprocket side. Cleaned the clutch plated with alcohol and paper towel and then re-oiled them. After reassembly and tonguing the clutch bolts to 8 ft/lbs the clutch is better, but the lever still requires a large amount of force to pull it.

While I had everything apart I check the clutch cable. It was easy to pull and smooth. I check the clutch screw and it was rotating smoothly.  Finely I tried removing 3 of the 6 springs and it felt "Right" Easy to pull and smooth. But leaving 3 springs out seems like a bad idea.

Lastly the clutch doesn't seem to be fully disengaging when I pull it.

If anyone has any ideas on what is going on or adjustments I can try please let me know.

Thanks

[Fazz711]

Have you checked the routing.

Had it in the past and it made big difference 

[gs7_11]

Check that the springs  aren't "heavy duty". Many people fit those thoughtlessly assuming they must be in some way better, or to compensate for worn plates.

Also, don't assume that a cable that feels free and smooth will be OK under load. If it's old, just get a new one. I've often found pattern cables inferior to OEM as well.

[wraith]

As above on both, check the rooting or re-root so there's no tite bends. I've had it before with a heavy clutch/ not working  properly that the cable was f++ked even though it seemed ok off the bike. Dose sound like you have HD springs in the clutch and with a badly rooted and or old cable it can make the clutch like something only Popeye could only use.

[johnr]

does the 550 have its lifter on the sprocket side of the engine? have you checked this mechanism?

[ProducerBill]

Yes the clutch cable is routed to the sprocket side of the crank case. I did check the clutch screw and it is dirty, but works smooth. I did think about putting it through a ultrasonic cleaning and re grease it.