Can’t hit Neutral when running.

[1PaulSilva]

I’ve read a lot of threads on this and I am out of ideas.

Bike: 1996 Suzuki VS1400 Intruder

Mileage: 19k

Issue: Bike will not shift into Neutral if the bike is running. The clutch lever has to be pulled in at a stop. Sometimes I can’t shift from second to first. If the bike isn’t running then I can shift through all gears perfectly.

What I have done:
Replaced Clutch
Rebuilt Master Cylinder
Rebuilt Slave Cylinder
New Clutch/Brake Fluid
Replaced Stator, Regulator and Battery
Rebuilt and Synched Carburetors

[Pio412]

Have you changed your clutch springs? and I'm assuming you changed your oil, correct?

[hillsy v2]

Yeah what oil are you running? It's a wet clutch system so the right type of oil is important.

[sgtcall]

Welcome!
Here are a couple of things to check out.

POSTING PICTURES ON INTRUDERS ALERT
viewtopic.php?f=19&t=13992

INTRUDER MANUALS AND INFORMATION
viewtopic.php?f=19&t=14168

[Lechy]

Try cleaning and lubricating the shifter linkage.

[Designer]

Issue: Bike will not shift into Neutral if the bike is running. The clutch lever has to be pulled in at a stop. Sometimes I can’t shift from second to first. If the bike isn’t running then I can shift through all gears perfectly.

Let me ask first to clarify,...when you say ..."if the bike is running"...does that mean when the engine is running,...or does running mean when the bike is in motion? This might make a difference.

[1PaulSilva]

By running I mean with the engine On, not sure what you mean by in motion since it would have to be running to be in motion. If it is not running, engine Off then I can find Neutral no problem.

The oil, filter, gear oil and spark plugs were also changed. The previous owner ran only Suzuki fluids so I stuck with that but I run RedLine products in all my other bikes.

The clutch springs were also replaced when the clutch was replaced.

[hillsy v2]

By running I mean with the engine On, not sure what you mean by in motion since it would have to be running to be in motion. If it is not running, engine Off then I can find Neutral no problem.

The oil, filter, gear oil and spark plugs were also changed. The previous owner ran only Suzuki fluids so I stuck with that but I run RedLine products in all my other bikes.

The clutch springs were also replaced when the clutch was replaced.

You were pretty clear with your description initially.

The problem is the clutch is slightly dragging for some reason. This could be oil, warped plates or the actuation of the clutch.

Did the problem start after the clutch was replaced? Genuine clutch or aftermarket? Sometimes aftermarket clutch packs can be thicker than OEM and this can cause issues. Did you replace both friction and steel plates?

[Designer]

By running I mean with the engine On, not sure what you mean by in motion since it would have to be running to be in motion. If it is not running, engine Off then I can find Neutral no problem.

By my question I was asking,.... did you mean you can't shift into neutral while sitting still with engine running.....as opposed to you Riding The Bike (which could be,.."running down the road" ) and trying to shift into neutral (obviously engine running at that time)

These two are different situations and, to be absolutely clear, we need to make sure as that can make a difference.

[navigator]

A few questions for you:
as hillsy asks, OEM or aftermarket plates?
Both steels and friction plates?
did the odd, thickest friction plate go on first? (inboard)
Is the wave washer in the correct orientation?
Did you replace the worn brass pusher located in the clutch lever? That could limit travel.
I still feel air trapped in the system can cause this issue.

[Herb]

My 87 started giving this kind of problem. Had problems shifting to neutral with the engine running at a stop. I could feel the bike pulling with the clutch lever all the way in.

Inspection showed the clutch lever where the brass busing goes in to push on the MC piston was worn and the pivot point was worn. Replaced the Lever and the problem went away.

[1lowcountry]

Could be off base here, but isn't there a possibility that air in the system is keeping the clutch from fully disengaging?

Have you tried a thorough bleed?

Also, can you tell at what point the clutch starts to engage when releasing the lever?

[1PaulSilva]

OEM Clutch replaced everything, the con-caved ring and odd sized plate are correctly installed.

I reverse bled the system and the clutch lever definitely has tension when pulled.

The problem already existed when I bought it. Every stop I have to have the clutch pulled in and if I try to find Neutral while approaching a stop then I can’t get to Neutral or 1st.

I have not replaced the brass push rod attached to the lever.

The only other thing I can think of filing the clutch basket down if there’s any grooves worn in.

[sgtcall]

Shot in the dark here.

For anyone, Could this have anything to do with mixing up the long and short bolts?

For 1PaulSilva, did you soak the plates before installing them? If so how long and in what?

[Designer]

Shot in the dark here. For anyone, Could this have anything to do with mixing up the long and short bolts?

Yes,. it very well could.
Seeing as how this problem existed before the clutch change, it's not likely it has anything to do with the New Plates nor how long they were soaked.
It is possible though the Bolts were installed wrong before the clutch change. As we have seen, even with a properly installed set of Plates/Washer, this issue can result in uneven clutch performance.

[1PaulSilva]

The clutch plates were soaked between 36-48 hours.

The springs were installed as in this video:

[1PaulSilva]

If the bolts are installed correctly I am seriously out of ideas other then taking a file to the basket if there’s any worn grooves.

[sgtcall]

You may have a few small air bubbles in the clutch line. Intruders are a PIA to bleed the lines.

Have you looked at the clutch slave cylinder?

Or tried something simple like some PB Blaster on the shifter shaft? Just to make sure it's not gunked up.

[1PaulSilva]

I rebuilt the slave so I am going to pull it back off and make sure when I pull the lever it’s working properly.

I’ll go ahead and remove the entire shifter assembly, clean, lube, reinstall and adjust.

Then I’ll bleed the system again to see if there’s still air.

I’ll report back with results.

[sgtcall]

I rebuilt the slave so I am going to pull it back off and make sure when I pull the lever it’s working properly.

I’ll go ahead and remove the entire shifter assembly, clean, lube, reinstall and adjust.

Then I’ll bleed the system again to see if there’s still air.

I’ll report back with results.

You might want to check this out for the clutch bleeding.
https://www.intruderalert.ca/indexa.htm