New clutch cable, clutch now constantly engaged?

[dan.porter15]

Hi all!

First of all this is for a 1992 GS500E.

I've been tinkering with this issue for what seems like forever. I took the front cover for the sprocket off just to check my front sprocket, and I thought since it was off and my clutch cable was stiff, I may aswell replace it.

After going to the garage, purchasing a new one and fitting it, it looks as though my bikes clutch is constantly engaged. When I start my bike and shift into gear, even with the clutch let out it still ticks over.

I've tried adjusting it from the clutch lever and tried bolting it all the way in and gradually unbolting the cable from the cover.

Also, I've read that the clutch adjuster behind the two phillips screwed should be adjusted so that when you feel resistance, you unscrew it a quarter way out and then put the bolt back on. I don't feel any resistance until the screw is all the way in, by which time I can't get that 10mm nut back onto the screw.

There doesn't seem to be any detailed videos or tutorials on how to do this step by step. I've done this on 125cc motorcycles before but they didn't have that clutch adjuster (I'm not sure what the techincal term is haha) behind the philips screws.

Any advice?

Thanks in advance!

[Kickstart]

Hi

Is the clutch pushrod in place? On some bikes the pushrod pushes on a ball bearing; has that ball bearing come out?

All the best

Katy
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[Triton Thrasher]

That's constantly disengaged.

Was there free play in the new cable before you messed about with the adjuster screw.

Could you have missed the resistance of the adjuster pushing the clutch off, against the springs, as you screwed it in?

That sort of adjuster on many bikes is screwed out until really free to turn, then screwed in until you feel it touch the clutch, then backed out the recommended amount. But you do that before you adjust the cable.
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Rrrrrrrrrrrrrrrrrr

[dan.porter15]

I can't see a ball bearing on the rod or anywhere in the mechanism, that could well be the problem! Is it just a small ball bearing?

There was quite a bit of free play in the cable before I did anything with the adjuster screw. The only bit of resistance I can feel is when the screw is practically the whole way in like in the picture. Apologies if that sounds a bit vague, I'm new to this haha

Thanks for the quick responses!

[Baggyman]

diagrams here: https://www.cmsnl.com/suzuki-gs500_model13447/

which one is it?
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Old fart
Baghira, modded GS1000 and the T150 I bought in 1978 when I was 21

[dan.porter15]

I think it's this one here

https://images.cmsnl.com/img/partslists/suzuki-gs500e-1992-n-e01-e02-e04-e16-e17-e18-e21-e22-e24-e25-e53-clutch_bigsue0048fig-15_2207.gif

Not sure where any ball bearing is on that image though, I can't read it very well

[Baggyman]

Clicking on it takes you to a numbered list so you can check what everything is.

Do you still have the old cable?

First thing to check is that the old and the new are the same - particularly the inner and outer length difference

Check both ends of the outer are seated properly as this will effectively change the working length (e.g. not too fat to fit in something)
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Old fart
Baghira, modded GS1000 and the T150 I bought in 1978 when I was 21

[dan.porter15]

The old and the new clutch cable appear to be identical, and when I try to fit the old cable again the same thing happens. There must be something I'm missing?

More pics attached... ignore the gunk

[Baggyman]

Can't see what is going on from that. Can you zoom out a bit so it shows everything at once?
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Old fart
Baghira, modded GS1000 and the T150 I bought in 1978 when I was 21