• Required reading for all forum users!!!

    Welcome!
    Register to access the full functionality of the GSResources forum. Until you register and activate your account you will not have full forum access, nor will you be able to post or reply to messages.

    A note to new registrants...
    All new forum registrations must be activated via email before you have full access to the forum.

    A Special Note about Email accounts!
    DO NOT SIGN UP USING hotmail, outlook, gmx, sbcglobal, att, bellsouth or email.com. They delete our forum signup emails.

    A note to old forum members...
    I receive numerous requests from people who can no longer log in because their accounts were deleted. As mentioned in the forum FAQ, user accounts are deleted if you haven't logged in for the past 6 months. If you can't log in, then create a new forum account. If you don't get an error message, then check your email account for an activation message. If you get a message stating that the email address is already in use, then your account still exists so follow the instructions in the forum FAQ for resetting your password.

    Have you forgotten your password or have a new email address? Then read the forum FAQ for details on how to reset it.

    Any email requests for "can't log in anymore" problems or "lost my password" problems will be deleted. Read the forum FAQ and follow the instructions there - that's what we have one for...

  • Returning Visitors

    If you are a returning visitor who never received your confirmation email, then odds are your email provider is blockinig emails from our server. The only thing that can be done to get around this is you will have to try creating another forum account using an email address from another domain.

    If you are a returning visitor to the forum and can't log in using your old forum name and password but used to be able to then chances are your account is deleted. Purges of the databases are done regularly. You will have to create a new forum account and you should be all set.

Clutch cable replacement how-to

  • Thread starter Thread starter elwaxoro
  • Start date Start date
E

elwaxoro

Guest
Following are instructions for replacing the clutch cable on a 1981 GS550L.

My first how-to! Keep in mind that I'm a newbie and pretty much figuring this out as I go along.
Please add comments/corrections- once it's reasonably coherent, I'll convert it to PDF and stash it somewhere for prosperity.

1. Remove left foot rest. This is probably optional, but I found it easier to take the extra 30 seconds and remove it.
 
2. Remove bolt and pull shifter linkage(?) away. Leave the pivot part alone.
 
Last edited:
3. Rotate shifter away

4. Remove 6 marked screws. I had to use an impact screwdriver to loosen these.
 
5. Remove cover. This takes some minor wiggling, but with the shifter and foot rest out of the way it is pretty easy.
 
Here's the other side of the cover. I cleaned most of the gravel and crud out of here already. I just let this hang here while I detached the cable from the other end.
 
6. Detach cable from lever. Just unscrew and remove- the slots in the bolt and nut line up to free the cable.
 
7. With the adjuster bolt out, just rotate the cable out of the slot and bring it down to free it.
 
8. Detach cable from cover. Rotate as shown in the picture until there is enough room to slide the cable and nut out. This works pretty much like the connection at the other end.
 
9. Remove and save the end. This will go back on the new cable.
 
10. Unscrew and remove cable from cover. This is a good time to clean the crud out.
 
11. Remove the gas tank (optional?). I opted to leave the tank connected and rotate it out of the way. Make sure to put a rag between the tank and anything that might scratch it.

12. Note routing of old cable, then remove it.

-- from here on out, pretty much follow steps in reverse to reassemble --

13. Install new cable along same path. I found it easier to go from the bottom up to the handlebars- as the handlebar end of the cable is smaller.

14. Attach cable to lever. Screw the adjustment bolt most of the way in to give maximum slack at the other end.

15. Attach cable to cover: insert cable end, screw in bolt, attach end nut, insert nut and cable into slot.
 
Last edited:
16. Reattach everything (cover, shifter, foot rest, gas tank)

17. Verify routing is correct, make sure there are no kinks, and be especially sure that the cable won't bind anywhere when you turn.

18. Set adjustment screws to the required tightness. I like mine with about 1/4" of play in the lever. Once set, tighten the nuts at both ends of the cable so everything stays put.

19. Test drive!

20. Beer!

PS: Nessism: the exhaust you sent looks pretty good on there, eh? :D
 
Last edited:
You must log in or register to reply here.
Back
Top