Changing springs and clutch cable tips?

[tkent02]

With all the linkage intact, squeezing the clutch puts outward pressure on the cover. Might pop it off by itself. Then if you still need it, do as Mike of BBG recommended, or just tap on the oil cap (not the handle, the edge of the cap) with a board and a mallet from the other side.

[littleroot]

Clutch cover is off, tapping with wood was perfect idea, springs are changed, new gasket with thin motor oil spread on both sides along the edge is hanging on the two mate studs.But I am having some trouble getting the cover back on. Unfortunately I had already removed the linkage. Going to work it back and forth a bit and see if I can get the part poking out of the middle of the clutch to mate with the cover.

[littleroot]

Got it on. I put the linkage back on and jilggled it back and forth and it went on. Time to bolt it back on - I will be using blue locktite

[littleroot]

Clutch cable is on and wow is it hard to pull now with the new springs. No test drive as it just started raining and I am beat. Thanks everyone for your help!

[Steve]

Clutch cable is on and wow is it hard to pull now with the new springs.

Did you get official, stock SUZUKI springs?

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[koolaid_kid]

I would be concerned at this point. Prior to the test ride, I would recheck the routing of the cable to make sure there is not any binding occurring. Although others do not do this, I always pre-lube my new cables prior to installation.
Other than that, is there binding inside the clutch cover itself?
The pull should be easy and smooth throughout the travel of the lever.

[tkent02]

Is the lever on the clutch cover at a 90 degree angle to the cable?

[Steve]

One other thing to check (you will have to remove the cover to check it, though):

I think the rod that goes from the top of the clutch cover down to the middle (official name is Pinion, Release) has teeth all the way around it, but it needs to engage the teeth on the mechanism that pushes on the clutch (Rack, Release). It is possible that you might not have the teeth properly engaged, or, if there are not teeth all the way around the Pinion, Release, you might be on the last tooth, and trying to pull on the Rack, Release with a solid rod instead of a tooth.

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[littleroot]

Hi guys,

Following morning when I was not as tired I found it not too hard to pull. Seems OK, but I would think if it was really grabbing the front wheel would come up a bit more when pushed hard, if you know what I mean. My 82GS1100GL seems to launch a lot more. But it's better. I should have done what Bill/Chef told me at Tom's memorial last night and pulled the fibers while i had the cover off. Well, I have an extra gasket so maybe I will.

Lever is at 90 degrees.

I'm not sure what you mean, Steve, but maybe if I look at the parts fiche I will understand.

And yes they were "stock" or OEM. I listed the Suzuki part numbers when I started this thread. :-)

Thanks again guys.

[koolaid_kid]

Yes, I would have pulled the discs out, knocked the glaze off the fibers, polished the steels, and removed any burrs from the clutch basket.
Your lever position is indeterminate at this time, since you removed it prior to removing the cover. What I mean is there is a relationship established between the lever position and the position of the internals of the Release Pinion. You may have altered that relationship when you removed the lever and then re-installed it.

[littleroot]

Sigh. Live and learn!

[koolaid_kid]

How do you think we figured it out?
And most of us did not have this forum to help us learn. Well, many of us did not have computers, because they were not around back then, much less the Internet.

[rapidray]

With all the linkage intact, squeezing the clutch puts outward pressure on the cover. Might pop it off by itself.

Sorry but this is wrong. Squeezing the clutch lever makes the cover pull IN. Ray.
.

[mrbill5491]

Sorry but this is wrong. Squeezing the clutch lever makes the cover pull IN. Ray.
.

I believe Tkent is right it puts pressure outwards on the clutch cover. As the rack is pulled into the clutch release you would have the opposing force out on the cover no?