How to remove a broken speedometer cable

[Guest]

Hi all, I just picked up a 1980 Suzuki GS550 and was going to replace the speedometer cable but I'm stuck with a problem. The knurled connector where the cable goes into the motor is broken completely flat against the speed sensor. I've got a repair manual in the mail that will hopefully help but I'm looking for some ideas here while I wait.

Any idea of how to get the speedo cable removed on the engine side without the knurled knob?

Thanks in advance for your input.

[JamesWhut?]

I think your first problem is that your speedometer cable is going to the tachometer output instead of the speedometer one on the front wheel.

[papcie03]

Woops, sorry about that, it's been a long day. I'm talking about the tachometer cable. Thanks for the correction.

[cowboyup3371]

Welcome to the site. Can you post up a picture of what you are seeing? I'm a little lost as to what you are referring to as the speedometer cable should just run down to the wheel while the tachometer cable goes into the motor. Which one are you referring to? If the speedometer, can you get the wheel off with the cable still attached to the mechanism and then use a pair of vise grips to loosen it?

If the tachometer cable, you'll want to loosen the valve cover, slide it to the right side of the bike slightly, and then try the same; or disconnect it from the tachometer and remove it completely from the bike and use the vise grips to rotate it.

[papcie03]

IMG_0967.jpgThanks for the quick response. Here is a picture of what I am talking about. You are correct, it is the tachometer cable. When I got the bike, only about 1/4 of the knurled end was left and that broke off the first time I tried to loosen it.

[JamesWhut?]

That is because the entire thing comes off. The little bolt holds a keeper. Remove that and everything above the head cover comes off. Then you remove the do-dad from the end of the cable. Don't worry, we've all done things like that learning how to wrench.

[Crankthat]

All you will need to do is wrench the part that is sticking out of the aluminum off in the same direction as a normal bolt.
You may need a pair of vice grips.

You can take the whole assembly out but then you will have trouble wrenching the part of cable still there without damaging the assembly trying to hold onto it.

[papcie03]

The metal cable end just spins in the housing. I removed the keeper screw and am starting to feel a little stupid. Is there a secret to actually removing the assembly? Is it just wiggle and pull? Thanks again for the quick help.

[JamesWhut?]

Yes. Just wiggle and pull. There is an o-ring seal holding it in.

Parts schematics are almost as good as having a manual...

http://www.cmsnl.com/suzuki-gs550-l-1980-usa_model16033/partslist/93248.html#results

[papcie03]

Aha I see. Thanks for the link. I've killed all my daylight now but I'll give it another shot tomorrow. I think once I get the assembly off the bike I'll be able to get the broken cable out. Thanks again.

[mrbill5491]

Replace the oring on the housing when you reinstall it. It is a tight fit and tends to damage the oring when it is removed.

[JTGS850GL]

To help in removing it, you can use a slotted screwdriver. Insert it into the slot on the tach drive housing where the small plate was in. Pry it out using the screwdriver. As it move out, you can use another screwdriver as a pivot. If that's still not enough to get it out, then use a larger screwdriver as a pivot further out. Eventually it will just come out by hand.

[papcie03]

I got it out, thanks for the tips. I decided to just order a NOS assembly and o-rings. Less than $30 and worth saving the hassle of figuring out how to get the broken cable out of the assembly.