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clutch release - correct installation and cable adjustment

  • Thread starter Thread starter crc1214
  • Start date Start date
C

crc1214

Guest
Allright, got all the sidecovers to the engine painted and started re-installing them lastnight, and got to the last one - the one on the clutch side that covers the clutch/clutch release/front sprocket.

And that's where I ran into problems. I re-installed (screwed in the clutch release mechanism to the side cover mounting holes) the best I knew how (I assumed you twist the release counter clockwise until its locked, then re-assemble the clutch cable to it, then stretch the little spring down until its locked in, then carefully remount the sidecover and screw everything in).

So everthing was screwed in, and I go to adjust the clutch cable (it was nothing but slack). So I loosen the adjuster screw (that mounts on top of that same sidecover) (make it so more of the visible part is longer), and still slack, and keep going and going and going until almost all of the screw is visible, and still slack.

So I unscrewed everything, and tried this again for about two hours with every variable changed that I could think of (started with the adjuster screw all the way out, and made it shorter after remounting, started the procedure with the clutch release in different positions to start with, etc.) and still no luck in getting resistance in the clutch cable.

Please help! I've been working on this thing far too much and need to enjoy the fruits of my labor this weekend on a nice spring ride.
 
What bike? Model.......

Did you change the clutch? or just disassemble it?
Or not touch and took the cover off?
 
There is a Gear that engages the Clutch Push Rod..

Try taking your cable back off, and then rotating it COUNTER Clockwise (left when looking at it from Directly above) to see if it is catching on the Push Rod.

Did you remove the PushRod when you took the cover off, and forget to place it back in when you put the cover on?
(I know that sounds silly, but things happen )

Let us know what you find.

Peace,
Busafied
 
Solved the problem!!! I read on-line somewhere about loosening the nut on the clutch release mechanism, then backing out the little screw about 3 turns, then tightening back to where you feel some tension, back out about 1/2 rotation, and tighten the nut back up. Went back up to the clutch lever after doing this and minor adjustment to the cable adjust screw was needed to get it back in order!!!

By the way, the bike is a 1978 GS550E.

One other question though..... when I put the clutch foot lever back on the clutch rod, and tightened it down in the correct position, I pushed on it without pressing in on the clutch handlebar lever and it went down into first, then up to second, then up to third (without any grinding) (I realize to get any higher than this I would have to actually be riding the bike). Is this normal??? Should I be able to put it into gear without depressing the clutch handlebar lever like that? Or is the explanation something like this.... shifting into gears can be done without the clutch lever depressed, but I'll tear up the gears in the process, especially if the rear wheel was actually moving, and I should really stop.

Thanks guys.

Chad
Columbus, OH 1978 GS550E.
 
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