New Guy - Clutch Cable Replacement

[wheressinatra]

Hi Everyone,

I am new to motorcycle ownership and bought a 1979 Suzuki GS 550 L about two months ago. It has been an excellent bike so far, but a couple weeks ago my clutch cable snapped while I was stopping. I was able to limp the bike home and ordered a new clutch cable (appears to be an OEM cable).

My first question has to do with whether or not it would be wise to drain the oil before I replace the clutch cable. I am not really familiar with how motorcycle engines/transmissions work so I guess I do not know if the clutch uses the same oil as the engine,etc.

My second question is whether or need I need to take off the clutch pedal in order to replace my clutch cable. I am having one heck of a time getting the gearbox cover out of the way (I am convinced the screws have not been removed in over 28 years!)

I bought a owners manual but it really does not go over clutch cable replacement and really has not helped at all.

Thanks in advance for any help and I will include a picture below of where I am at with my removal of covers.

http://picasaweb.google.com/jakecarleen/UntitledAlbum/photo#5074203500374500962

[chef1366]

You don't have to drain the oil to change the cable. That basically is a sprocket cover with the clutch cable running trough it.

[wheressinatra]

Thanks a bunch chef1366,

So I take it that I do have to take off the larger cover? It appears to me that taking off the larger cover would mean I have to take off the clutch pedal.

Or do I just need to loosen that exposed nut (see picture in first post) to access clutch cable?

Thanks in advance.

[catfishk]

on my cycle, a few years later but basically the same layout, this job was much more of a pain than the manual stated. i had to remove the shifting mechanism AND the foot peg, which is sandwiched between the frame and the aluminium stuff at the swing arm pivot. all of this was in order to remove the side cover you have pictured (again, mine is different) and unclip the cable inside.
you don't need to drain anything. the only things in there are the chain drive sprocket and the clutch pushrod. the cable and clutch actuator are attached to the inside of the cover. nothing should fall out or spill.

i am not sure what you mean by clutch pedal, but after i got the foot peg and shifting assembly off, the replacement of the cable was an easy job. however, my 'E' model seems to have the foot peg moved around to be more sporty, so your cover might just slide off when unbolted.

[catfishk]

oh, i forgot. MARK THE POSITION OF THE GEAR SHIFT ACTUATOR ON THE SPLINE BEFORE DISSASEMBLY. you don't want to have to monkey with it when you put it together and can't find your gears a sharpy or white out will do if you don't get it greasy.

[mriddle]

An impact driver is useful for removing those stubborn screws on the side covers.

http://www.sears.com/sr/javasr/product.do?BV_UseBVCookie=Yes&pid=00947641000&cat=Mechanics+Tools&subcat=Automotive+Specialty+Tools&vertical=TOOL&ihtoken=1

Mike

[matt_gs450]

I had the exact same thing happen to me with my bike. I was riding and all of a sudden .. *snap* .. there went the clutch cable.

And, like you, I had problems getting the clutch cover off due to frozen and/or stripped screws.

Try an impact driver (as suggested above) first. Still, if any screws are stripped, you may need to destroy them to get them out. Therefore you should have a set of replacement screws for any screws you have to destroy.

I documented my clutch cable replacement. It may help:

http://www.stupidcatchphrase.com/moto/gs450t/clutch-cable-replace/index.html

-Matt

[matt_gs450]

Here is the link to the replacement hex bolts for your various covers:
http://www.z1enterprises.com/detail.aspx?ID=1168

I would highly recommend buying this set and replacing the screws as needed.

[wheressinatra]

Thanks everyone,

I have all but one screw out at this point and have pretty much destroyed every screw. The impact driver helped on a couple, but it appears that the previous owner may have tried to take the clutch cover off at some point so a bunch of the screws were stripped before I got to them.

I ordered some new bolts and will hopefully be able to continue with the job once they arrive.

Thanks a bunch for the help.

-Jake

[Gerg Left]

I also had my clutch cable snap, I"ve gone through this and I have the cover off, I've routed the cable through the bike. My problem is as I pull the clutch lever in, there is little to no tension [the spring inside the case is connected], to pull the clutch lever back out. Is this just a weak spring [not I haven't put the cover back on the bike yet, encase that is where some of the tension to pull back. Help appreciated.

[Killer2600]

I also had my clutch cable snap, I"ve gone through this and I have the cover off, I've routed the cable through the bike. My problem is as I pull the clutch lever in, there is little to no tension [the spring inside the case is connected], to pull the clutch lever back out. Is this just a weak spring [not I haven't put the cover back on the bike yet, encase that is where some of the tension to pull back. Help appreciated.

The tension comes from the clutch springs so everything has to be hooked up for you to be able to feel the clutch.