clutch cable adjustment

[dfinnegan71]

here's the scenario, last week I changed out the clutch cable on my ol' girl. 1980 GS 550 L. I did this because the old cable was adjusted all the way out on the lever and where it goes into the cover at the engine, both adjustment screws all the way out on the last thread. So a new cable was ordered, I installed it and All was fine until tonight on the way home. I felt the lever grabbing closer to the bar, than I turn out the lever adjuster....repeat every few miles. Now the adjusters are all the way out again at the lever and at the engine cover and it won't disengage at all. What do you think is going on?

[Steve]

I think you need to adjust the clutch properly.

Do you not have a manual for your bike?

Start by turning the adjusters at the handle and where the cable goes into the motor all the way IN. Remove the cover behind the gearshift lever, adjust the locknut and setscrew on the clutch pushrod for minimal play. Put the cover back on, do some fine-tuning where the cable goes into the motor. The adjuster at the lever can then be used to handle any "stretch" in the cable.

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[dfinnegan71]

sounds like your right Steve. I'll have a look a the locknut and set screw. No I don't have a manual. But BASSCLIFF does!

[dfinnegan71]

Can someone walk me through the adjustment? Do you turn clockwise? How far do I go? any help would be awesome! Thanks!

[tkent02]

With all the cables adjusters adjusted full loose, turn the setscrew out and then back in until it just touches, back it out 1/4 turn (1/2 turn? can't remember) then set the locknut. Adjust the lower cable adjustment to get the right amount of lever free play, save the one on the clutch perch for last, to fine tune it.

Before you do all this, taking the helix out to clean and grease it will help everything work smoothly. Usually the return spring in there is messed up too, look at that while you are in there.

But it's all in your service manual.

[tkent02]

a new cable was ordered, I installed it and All was fine until tonight on the way home. I felt the lever grabbing closer to the bar, than I turn out the lever adjuster....repeat every few miles.

Just read this again. Sounds like you new cable is breaking. If the round bearing that fits into the lever isn't turning, the new cable must bend every time the lever is pulled, it could be breaking strands of wire already. The bearing needs to be lubed, the hole in the lever needs to be round, the perch needs to be operating smoothly. Also sometimes the threads on the adjuster dig into the cabe and will make it break very quickly.

[blowerbike]

worm gear!

[dfinnegan71]

It turns out, no pun intended, that my lock nut was all the way loose and almost off the set screw. All is readjusted and working properly. Thanks!