1980 1000G Clutch cable repair...

[Blaise Barshaw]

I just took out a broken clutch cable. My new one appears to be the same length as the old one but I cant seem to get it "tight" enough, no matter how I adjust it at either end.
The old cable I took out had an "adjustment screw thing" about half way up the cable. I rechecked my part I got and it appears to be "correct" part number for a replacement. Any suggestions?????

[chef1366]

Even if you barely thread the clutch cable at the lower point and have the upper adjustment all the way out it doesn't fit? It doesn't fit. Is it a Suzuki part?

[salty_monk]

My new cable also had the screw together part in the middle like the old one... Yours is probably aftermarket.

If you have the adjuster all the way out top & bottom, try moving the actuator on the bottom (where the cable hooks in) around clockwise on it's pivot by a spline or two & seeing if that works. It should move it out & take up the slack. You have to remove that little bolt (10mm head from memory) all the way to get the actuator off the splines as it has a groove halfway down the spline to hold it.

Dan

[Blaise Barshaw]

My new cable also had the screw together part in the middle like the old one... Yours is probably aftermarket.

If you have the adjuster all the way out top & bottom, try moving the actuator on the bottom (where the cable hooks in) around clockwise on it's pivot by a spline or two & seeing if that works. It should move it out & take up the slack. You have to remove that little bolt (10mm head from memory) all the way to get the actuator off the splines as it has a groove halfway down the spline to hold it.

Dan

I'll give that a try-the new cable is Suzuki part. Thanks

[salty_monk]

The as long as the inner & outer cable are proportionally the right lengths then any cable should do it. Within reason (i.e. if it will reach or if you can loose any excess behind the light bucket) any length suzuki GS cable will work on any other.

If you have the bottom adjuster maxed out & it almost works (i.e it pulls about half clutch) you are about 1 spline out from memory, maybe two. You could be three or more.

It normally happens because people remove the actuator but forget to reset the splined pivot all the way to one side (you'll see it has about 1/4 turn or so of free play in it) before refitting it.

I've done it, that's how I know