Clutch cable replacement problem

[Guest]

Hey guys, I've read for a while, but this is my first post. I've run into a problem. After replacing the clutch cable on my brother's 77 GS750, we can't seem to get the clutch to disengage. We ran into the common problem with the shift drum being disoriented against the engine's position. We can work the transmission back into place (meaning that it will travel through all of the gears), but once we re-attach the linkage and set the tension on the clutch cable, the clutch will still not engage when the handle is squeezed. This bike had been a daily commuter with no transmission problems until the cable was changed. Does anyone have any ideas?

Thanks,
Nate

[geol]

Sure. remove the pin that is retained by a cotter pin on the arm that actuates the clutch. Rotate the knurled end that sticks out of your clutch cover counter clockwise. It will go about 1/4 turn. Then reattach the arm onto the knurled bit that sticks out of the cover and adjust the cable tension.

[allojohn]

Loosen the cable, take off the cover and loosen the lock nut, loosen the worm-screw, turn the worm-screw in until you feel resistance, back it out 1/4 turn, tighten locknut. Replace cover, adjust cable.

[Nessism]

If you removed the helix from the case there is a good chance that it got put back in the wrong orientation.

[fireeight]

If you removed the helix from the case there is a good chance that it got put back in the wrong orientation.

It was removed. My Clymer manual doesn't really cover how to re-orient it. Any way you'd be able to elaborate?

[Nessism]

It was removed. My Clymer manual doesn't really cover how to re-orient it. Any way you'd be able to elaborate?

You have to put it back in the same orientation that it was removed. Go back and pull it out again and try sticking it back in in various positions and you will see what I mean. Of course, you should be filling the grooves with fresh grease during install.

Of course you will have to adjust the cable too. Use the procedure listed in the factory Suzuki service manual. If you don't have one find basscliff's website and download one.