HELP!!! I broke my baby!!!!

[apr35]

I have a 2005 GS500F who is ill.

Any ideas of what might be wrong would be greatly appreciated! 

Heres what happened

So I had to change my clutch's hand lever, it snapped in my one and only bike drop and I had the new one ready to go.

In the process of loosing the clutch cable to remove the old hand lever I must have pulled it to tightly because I heard a loud SNAP!! noise. 

So of course, after hearing the noise I expected to pull the cable right out because it had snapped, WRONG!  There was still a bunch on tension when I out everything back together, it felt the same as it always has.  I figured great, I didn't do as much damage as I thought. 

So once everything is back together I figure I have to start it up and take it for a quick spin, and this is when I begin to CRY!!!  She would not start at all.  I have to hold the clutch in to start so I realized the clutch may not be engaging.  I but the bike in gear and tried to roll it, it is a tiny bit easier to role when the clutch is pulled in, but much more difficult than when the bike is actually in neutral. 

All of these facts have led me to believe that the clutch is not engaging.  I called a repair shop and they told me to make sure there is a little give when I pull the clutch in, there is.  I took of the clutch cover and realized I have no idea if what is inside looks any different than it should.

I have no clue of what could be wrong, but if anyone can offer a bit of insight on either what is wrong or what you would do to fix it, it would be a Christmas Miracle!!!

Thanks for any help

Happy Holidays!!

[The Buddha]

You probably snapped the clutch switch wire ...
Cool.
Srinath.

[apr35]

any idea of where to start fixing if i snapped the clutch switch wire?

[Bob Broussard]

The only clutch switch I know of, is on the mount for the clutch lever. Never saw anything behind the sprocket cover.

The cable connects to the actuator inside the side case. When the cable pulls up on the actuator, it moves out, pushing the clutch rod . The actuator has threads on it like a big screw. It unscrewed enough to pop out and back in,
changing the position it sits at.
Pull the cover off and twist the actuator counterclockwise until it comes out. Then move it clockwise a bit and screw it back in. This will move the cable arm down a bit farther. Then when you pull the clutch lever, it will disengage the clutch more completely.

[wannabebiker2006]

Ok this probably isn't it but under the clutch perch there are 2 very tiny screws.  If you unscrew these you should be able to pull out a little white topped plastic piece that slides back and forth.  This piece, I can't remember what it is called right now, but it has to do with starting the bike with the clutch in.  CHeck to make sure you haven't damaged this in anyway and that the white plastic piece sits up in the groove on the clutch lever.

[The Buddha]

Starting in 96 they went to a single push in type thing with a spring activated plunger.
Much easier to screw up IMHO.
Either way your problem is there, more than likely.
Cool.
Srinath.

[apr35]

SO I took of the clutch cover and check things out.  Just like was fortold, I saw the lever with large threads that pushes on the clutch rod when the handle is pulled.  I moved it around, rethreaded it as you suggested, and still no luck at all.

The clutch rod seems like it is pushed in as far as it will ever go in, but the clutch is not engaged at all.  Is it possible when Pulling on the cable i pushed the clutch rod in so much that it broke something more internally.  The rod pull easily in and out of the area it fits, but again, when pushed in, feel like there is no chance it will go further.

Also, when I reset the actuater with the big threads, it was pushed out far too much to screw down the clutch cover again.  I was also told that when let out, the actuater should sit flush with the cover.

I probably do not sound like I am making sense at all, and as you can probably tell, I am not very mechanically minded. 

Is it time to find someone with a trailor and take my baby to the doctor??

All your replies have been appreciated, and other help would be great!!

[Affschnozel]

Inspect the obvious first.The cable might have been stretched and partialy broken and now doesn't have enough movement.