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clutch cable not connected?

  • Thread starter Thread starter kysteezy
  • Start date Start date
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kysteezy

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hey im new to ths forum as i have just bought a gs450l. i cant seem to fuigure out how the clutch cable connects to the mechanism. i think something small is broken but i am not positive. if theres any way that somebody could help me out and get a picture of the setup with the sprocket cover off it'd help a lot. thanks in advance kyle
 
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You'll find parts 21-30 under the left rear engine cover. The end of the cable hooks into part 30. Your cable has probably lost the lead end on it. When you install the new cable leave it very loose at first. Then loosen part 26 which will be located on the outside on the engine cover you removed. Turn part 25 until it lightly seats then back it off 1/4 to 1/2 turn and tighten the locknut while keeping the adjuster screw keld in place with a screwdriver. After that adjust the cable so you end up with 1/8" of play measured between the clutch lever and the perch it attaches to. You need a new cable and clean up the inside of the engine cover and grease the surfaces that move against each other on parts 21-30.
 
hmm i believe the cable is intact but part 30 i dont see in there. instead i have a U shaped metal piece that looks like somehow it hooks to the end of the cable. ill go take a picture of two real quick
 
Whatever looks like the obvious place to hook the cable up is it. Then just do the adjustment like I outlined.
 
this is what it looks like and i feel like im not seeing something
 
The piece that is hanging on the end of the cable has broken off from the piece just above the spring. Twist that part sideways from where it is oriented now and see if it doesn't look as if it has come apart. Either replace that part of the mechanism or get a cover off ebay.
 
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do you happen to know what that piece or assembly is called?
 
Neither Bike Bandit nor Alpha sports shows the part as inventory. Part 30 doesn't look right in the drawing but it is what you need. BTW, what year is your bike, not that it really matters? Honestly, your best bet might be to fab your own if you feel you can do it.
 
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its an 82. but yea i was thinking i could probably macgyver something together but im not sure what exactly i should do to connect them so it still works smoothly. Maybe welding the U shaped piece to the inside of the square [ ] piece?
 
kysteezy said:
its an 82. but yea i was thinking i could probably macgyver something together but im not sure what exactly i should do to connect them so it still works smoothly. Maybe welding the U shaped piece to the inside of the square [ ] piece?
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I'd just get some steel flat bar about the right size and bend one up. It doesn't need to be as intricate as what is there now. Unscrew the two philips head bolts and pull the hole push assembly off. There is a pin holding what is left of the lever the cable attaches to. Take the two broken pieces and get an idea of how to bend the bar to roughly match the old one. If it's not perfect it won't matter, you can get plenty of adjustment out of the cable. Then drill a hole the right size where the cable goes and cut a slot to run the cable through. Just don't fatigue the metal too much when you make your bends. Heating it will make it bend better without fatiguing. You'll drive yourself nuts trying to get just that part. It would be easier finding the entire cover on Ebay than to get just that part.
 
thanks for the advice i really aprrecitate it. ill keep things updated as i get down to business.
 
hey thanks for the help i ended up just doing a minor spot welds to attach the cable end to the pivot point and it works smooth as ever
 
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