need more help with 77 gs550

[beherenow71]

Well, the clutch push rod broke about a month ago. I finally got all the parts and put it back together. Right now, there is no resistance in the clutch lever, I can see that the cable is pulling but nothing is happening. I have yet to hook the battery back up and turn the bike on however. Is there something I did wrong(according to the manual I have everything back together right) or is there some trick I missed? I'm completely lost and need help badly please. Thanks

[Nessism]

Did you take the helix mechanism out of the side cover? If so, you might have index it incorrectly when you put it back in – the helix is not like a thread on a bolt, there are multiple threads so the indexing can be off. Assuming this is the case, remove the helix again and reinstall it after rotating in another position.

Good luck and hope this helps.

[beherenow71]

Is there anyway you could dumb that down a bit? What do you mean by helix mechanism? Is it on the left side or right side of the bike? A picture maybe? Is that the piece that the push rod goes into on the left side of the bike? This is my first time working on a clutch and I really don't know a lot. Thank you.

[Nessism]

It's on the left side cover - the mechanism that pushes on the push rod.

[beherenow71]

ok. Yea I did remove that piece. I actually had to replace it with a new one, because when the rod bent it cracked it. For adjusting it, is it the little nut thats on the back side of it? Is there another spot to adjust? How do I know how far to turn it?

Thanks again

[Nessism]

ok. Yea I did remove that piece. I actually had to replace it with a new one, because when the rod bent it cracked it. For adjusting it, is it the little nut thats on the back side of it? Is there another spot to adjust? How do I know how far to turn it?

Thanks again

As I said in my other post, that helix piece is most likely not indexed properly; there is more than one way to put it in. Pull the helix back out and rotate it (clockwise I think) before putting it back in - you want it sticking out farther than where it is now.

[Suzuki_Don]

Position the helix mechanism so that it's lever is directly underneath where the clutch cable enters the cover and slightly below 3 oclock position if that is possible. Place pushrod in position. Attach clutch cable to helix mechanism lever. Replace cover on engine temporarily, attach with a couple of screws. Remove slack in cable using adjuster in top of case.

Loosen locknut on outside of helix mechanism, turn adjustment screw out a couple of turns to make sure there is clearance between the other end of the screw and the pushrod. Then turn screw in until serious resistance is felt. Then back out screw 1/4 to 1/2 a turn. Tighten lock nut. Adjust cable adjuster on top of case to obtain 1/8" clearance at clutch lever. And all should be good.

If it is not or you cannot remove the slack from the cable and the clutch lever pulls all the way into the handlebar you may need to reposition the helix as Ed has said originally. But if you can get the adjustment screw to butt onto the end of the pushrod and feel resistance then all should be OK.

[beherenow71]

http://i297.photobucket.com/albums/mm239/beherenow71/09.gif

When you are saying "helix" you are talking about part #5 right?

[Nessism]

http://i297.photobucket.com/albums/m...renow71/09.gif


When you are saying "helix" you are talking about part #5 right?

Helix is inside that assembly.

Take the small spring off the clutch mechanism inside the cover, and remove the plastic "helix" gear. If you never took this out though, maybe we are barking up the wrong tree?

[beherenow71]

I replaced that entire mechanism, part #5