How to: assemble Clutch cable engine end, clutch release HELP

[cbbjoemama]

well i thought i made a thread last night but i must of not pressed post.

I put a new clutch cable on last night and everything seemed pretty self explanitory.

but when I got to the engine end of the cable to hook up to the clutch release lever, I unscrewed the threaded bolt that had a flat head screwdriver end on it (#9), which allowed me to take the little lever off(7).

since it had squared edges i figured it could only go back on one way.

I put everything back together with the new cable in its housing on the lever. Im getting no release when i pull the actual lever on the handlebar, the cable pulls on the lever and the only tension im feeling is from the spring.

here is a photo

when its all together 7 fits over the end of 6, and when 6 turns it should release the clutch, clutch worked fine before i took 8,9,10 off to get 7 off.

i can turn the end of number 6 real slow, 360 degrees either way. What is going on?

this prevented me from going to bike night last night at quaker, this is all i needed done to just ride down the street...

any advice would be appreciated, before i must take it in to a suzuki dealership.

hope i explained it well enough. any question or answers please feel free to chime in.

 

[Agemax]

have you screwed the threaded bolt back in far enough? i dont know much about these clutch actuators?

 

[Suzuki_Don]

No. 8 screws into No. 6 and bears on the end of the clutch pushrod. If you can turn the lever 360 degrees either way then this screw needs some adjustment. Screw No. 8 in till it bears on the end of the pushrod and then back it off 1/2 a turn for some slight clearance. Put it back together and it should work OK. The actuating lever should be pointing downwards at about 4 o'clock at the rest position and when fully actuated it should be at about the 2 o'clock position.

 

[Flyboy]

Have not done one of these in a while, let me see if I can remember..
As you correctly say, the arm with the two flat faces (7) goes over the end of 6 to turn it as you pull the cable.
When you install the adjuster (8) you need to screw it all the way in until it just, just touches up against the clutch rod (1), and then lock it with the nut (9) and you should be back in business.
Then set up your freeplay on the cable as usual.
Number 8 is an adjuster that is there to take up the free play as the clutch plates wear down.

 

[cbbjoemama]

Flyboy, SuzukiDon, Agemax...

thanks for all the advice. seems like this problem has risen before, im not home now but seems like that definatly is my problem. I cant remember tightening the headless screw all the way in, didnt know it hit the pushrod, i just thought it was there to hold the little lever on,

is that lever that the spring attached to called actuating lever? id like to call them by their proper names.

and when i was testing it and turning it 360degrees it looked just like the photo i snapped, i was spinning it without the screw and nut in place.

thanks again fellas. i might just end up keeping the GS for few years now. i did plan on selling it next season for another build, but this forum has given me so much info, it makes me wanna build another!

 

[Agemax]

Flyboy, SuzukiDon, Agemax...

thanks for all the advice. seems like this problem has risen before, im not home now but seems like that definatly is my problem. I cant remember tightening the headless screw all the way in, didnt know it hit the pushrod, i just thought it was there to hold the little lever on,

is that lever that the spring attached to called actuating lever? id like to call them by their proper names.

and when i was testing it and turning it 360degrees it looked just like the photo i snapped, i was spinning it without the screw and nut in place.

thanks again fellas. i might just end up keeping the GS for few years now. i did plan on selling it next season for another build, but this forum has given me so much info, it makes me wanna build another!

yes it is...... it actuates a cam which pushes the pushrod in. if the "headleess" screw is not in far enough then the lever will turn full circle as its not touching the push rod to actuate the clutch.
as mentioned, screw it in until it hits the pushrod then back it off maybe 1/4 turn. hold it with the screwdriver while tightening up the lock nut.
then adjust the cable accordingly

 

[cbbjoemama]

yes it is...... it actuates a cam which pushes the pushrod in. if the "headleess" screw is not in far enough then the lever will turn full circle as its not touching the push rod to actuate the clutch.
as mentioned, screw it in until it hits the pushrod then back it off maybe 1/4 turn. hold it with the screwdriver while tightening up the lock nut.
then adjust the cable accordingly

I can understand what I need to do to make it work, but im still a little confused on why I need to back it off about 1/4 turn. Wouldnt this make it not touch the push rod? Am I just pushing the push rod into a certain position? just seems weird because im butting up against it then coming off of it.

I dont know, all I care about is being able to engage the clutch HAHA

Thanks again

 

[chuck hahn]

see your post about can an 850 motor fit in a 750 frame i posted the adjustment process..i think you just didnt turn the adjusters and the pushrod screw in enough..its all good. It needs to come a bit off of the pushrod to be sure that the pressure plate is fully engaging the clutches and the steels together to eliminate any possible slippage.. there is enough travel in the cable to sufficiently engage and dsiengage the accuator.

 

[DanTheMan]

Here's where you posted your question, and Chuck's answer:http://www.thegsresources.com/_forum/showthread.php?p=1273061#post1273061

edit: Chuck beat me to it.

 

[Agemax]

I can understand what I need to do to make it work, but im still a little confused on why I need to back it off about 1/4 turn. Wouldnt this make it not touch the push rod? Am I just pushing the push rod into a certain position? just seems weird because im butting up against it then coming off of it.

I dont know, all I care about is being able to engage the clutch HAHA

Thanks again

its because you dont want the adjuster in permanent contact with the pushrod as it will spin with the engine when it is running and wear out your adjuster,pushrod and clutch release bearing. just a tiny gap will prevent this but still allow full clutch operation

 

[cbbjoemama]

see your post about can an 850 motor fit in a 750 frame i posted the adjustment process..i think you just didnt turn the adjusters and the pushrod screw in enough..its all good. It needs to come a bit off of the pushrod to be sure that the pressure plate is fully engaging the clutches and the steels together to eliminate any possible slippage.. there is enough travel in the cable to sufficiently engage and dsiengage the accuator.

Here's where you posted your question, and Chuck's answer:http://www.thegsresources.com/_forum/showthread.php?p=1273061#post1273061

edit: Chuck beat me to it.

Wow fellas. im pretty embarrased now. I didnt mean to double post, I really thought I made a thread, So this morning I checked to to see threads Ive made in my user profile, and it wasnt there.

I didnt mean to jack the 850 in a 750 thread, I was must have been half asleep and didnt realize.

But nonetheless it all makes sence now, why to back off the screw, I really thought I was gonna have to tear down the tranny and figure out what I did wrong.

Ill post new pics soon in my Projects thread, bought bunch of new things last night at the Iron Pony in Columbus OH, I just moved here and didnt even realize this "mini motorcycle heaven" was in my same zipcode. HAHA

Thanks for all your responses!

-Joe

 

[cbbjoemama]

got it fixed thanks man...without you guys i would have spend countless hours or money on labor for someone else to do it

 

[chuck hahn]

You can send a Money order for the sum of 1.95 Trillion dollars to

Charles hahn
PO BOX XXX
Twining MI 48766

Of course you are recieving the standard discount for being a GS Resources member as well!!

 

[cbbjoemama]

You can send a Money order for the sum of 1.95 Trillion dollars to

Charles hahn
PO BOX XXX
Twining MI 48766

Of course you are recieving the standard discount for being a GS Resources member as well!!

haha Chuck if i had it i would send it. Hows the weather in michigan, looks like we are neighbors.