Something wrong after clutch cable was changed

[legendprice]

Hey all I have a 1982 GS650E 18,000 iriginal miles, Anyways the clutch cable broke 2 weeks ago. So I ordered a replacement cable from Suzuki. exact replacement to spec. Now I changed the cable adjusted it correctly. It seems a bit tighter than before but it's a new cable. I have to pull in the clutch to start the bike! after it's started I pull in the clutch and place it in gear and nothing happens? I can go through the gears and nothing happens like it's stuck in nuetral but the gears are signaling 1,2,3,4,5, So now I really don't know what the problem is? I think it's something simple but need some Advice any suggestions would be appreciated. Gears and transmission worked fine before the old cable broke

[salty_monk]

Did you get it on at the correct angle at the bottom end? If you get that piece on the splines at the wrong angle it will either hold the clutch open (seems your problem) or not allow it to release.

You need to spin the spline release shaft until it touches the release rod & then add the arm on it at the right angle. That's if it's the same as the GS1000.

If it's the same as the 550 I suspect it's a similar issue, something to do with the Cam behind the sprocket cover I would think.

Dan

[Nessism]

The 650 clutch arm is on the clutch cover, just like the 1000. Regarding this problem, sounds like the cable is too tight and holding the clutch from engaging. Not sure what you took apart when you installed the cable but it sounds like you need to retrace your steps to find out where your cable freeplay went.

[posplayr]

The 650 clutch arm is on the clutch cover, just like the 1000. Regarding this problem, sounds like the cable is too tight and holding the clutch from engaging. Not sure what you took apart when you installed the cable but it sounds like you need to retrace your steps to find out where your cable freeplay went.

FYI Legendprice:

If the cable is too stiff to release then you can confirm by pushing on the arm to fully engage the clutch.

Also welcome aboard with your very first post. Nicely done.

[chef1366]

Is your drive chain installed?

[rudy]

Did you lube the cable before installing it?

[Nessism]

Did you lube the cable before installing it?

Why lube a brand new cable?

[posplayr]

Why lube a brand new cable?

Good measure

[rudy]

Cuz not all of them come pre-lubed. Mine didn't, but I didn't get the "Suzuki" ones. Motion-pro is dry.

[legendprice]

Clutch Cable replacement issue

Well the Suggestion the Salty offered seems to be something that may infact be the problem, However I suspect that he is refening to turning the gear at which the clutch cable connects to at the bottom of the cable connection (correct )? spline refrering to the gear with teeth where the adjuster mounts ? It does move manually with force, I just figured it was always a tight clutch as before the cable broke. So If I try and spin this spline as Salty AKA Dan refered to it as I assume it is a trial and error type of thing where I remove the attatchment from the teeth and turn it somehow to a less tight angle? is that the reccomendation Dan? Otherwise I am still stumped Yes I lubed the cable with the Cable lube Kit, Lube kit cost more than the cable it's self. I really don't want to take this bike to the shop because I think it is a reasonablely easy fix I just am not sure about the method, Additional Reccomendations and Advice would be greatly Appreciated Thanks for all the responses I got! I am glad to have joined this forum And I am going to post some photo's to share with ya all there is a great story behind how I got this bike too for $1.00 Yes one dollar

[tkent02]

The arm is about 90 degrees to the cable on the ones I have worked on if that helps.

[salty_monk]

Old pic but here is the fully released position on my 1000E which is the opposite of the 1000g



On the G you can just about see in this pic, the lever is rotated the other way so the cable connects at the front of the bike I think.... 650 is probably the same as this.



It can only be either top or bottom cable adjustment or where it is on the splines, there is nothing else you can adjust!

You shouldn't need to push that lever in past the point where it get hard to push in order to connect the cable. You should be able to fit it easily & then simply adjust until just before it gets to that point on the lower adjuster, fine tune with the upper.

Dan