3 point clutch adjustment

[CraiGDaniel]

Looking to spend a little time perfecting my clutch. The clutch adjustment at the lever is screwed right out and if i screw it out anymore it will fall out. However if i screw it back in the clutch is very limp.

I know there is a guide on the wiki but i didn't find it to helpful so was looking for ways the forum members personally adjust their clutches.

Thanks

[Suzuki Stevo]

Once your rough adjust #5 & #6 is done, use the cable length #3 & #4 and the adjustments at the lever #1 & #2 to put the lever where you want (closer to grip or farther) you must always maintain some freeplay at the lever.
1/4 turn out from bottomed with #6 is plenty 

[gsJack]

First pull back the boot at the handlebar clutch lever and loosen the lock wheel and turn the adjustment all the way in and lock.  Then loosen the locknut at the other end of the cable where it goes into the front sprocket cover housing and turn the cable adjustment in to give much more freeplay to unload the pushroad adjustment.

To adjust the clutch push rod freeplay remove the little cover on the sprocket housing held on by 2 phillips screws.  Loosen the locknut with a 10 mm socket and back out the slotted adjustment screw it holds with a screwdriver a turn or two until it's free of the pushrod.  Then while holding the locknut turn the screw back in until it contacts the rod and back out 1/4-1/2 turn to set freeplay and hold screw with screwdriver while locking down the locknut.  I clamp vicegrips on a deep 10 mm socket to tighten the locknut while holding the screw with the screwdriver inserted thru the socket.

Finally turn the clutch cable adjustment out of the housing to get proper clutch freeplay and tighten locknut.  The clutch lever adjustment at the handlebar will then be available for future freeplay adjustments.

[CraiGDaniel]

Appreciate it guys. Thank you

[nadgs]

so, I turned the adjustment at the lever all the way in. which way should i turn the adjustment at the sprocket cover to loosen the push rod, (in tot he cover or away from the cover) ?

I changed my clutch lever last night and mess up the whole adjustment. Now, it not even engaging.

First pull back the boot at the handlebar clutch lever and loosen the lock wheel and turn the adjustment all the way in and lock.  Then loosen the locknut at the other end of the cable where it goes into the front sprocket cover housing and turn the cable adjustment in to give much more freeplay to unload the pushroad adjustment.

To adjust the clutch push rod freeplay remove the little cover on the sprocket housing held on by 2 phillips screws.  Loosen the locknut with a 10 mm socket and back out the slotted adjustment screw it holds with a screwdriver a turn or two until it's free of the pushrod.  Then while holding the locknut turn the screw back in until it contacts the rod and back out 1/4-1/2 turn to set freeplay and hold screw with screwdriver while locking down the locknut.  I clamp vicegrips on a deep 10 mm socket to tighten the locknut while holding the screw with the screwdriver inserted thru the socket.

Finally turn the clutch cable adjustment out of the housing to get proper clutch freeplay and tighten locknut.  The clutch lever adjustment at the handlebar will then be available for future freeplay adjustments.

[gsJack]

Turn adjustment into the front sprocket cover.  You are shortening the effective length of the outer cable so the inner cable will reach thru further to relax the lever inside.

From shop manual:

http://img.photobucket.com/albums/v443/jcp8832/GS500clutchadjustment_zps58ca4ce8.jpg

[nadgs]

I will try it  . I think I turned that away from the sprocket cover and played with the adjustment screw, ended up with a tight clutch lever. 

[nadgs]

I tried just as you said, but I can still feel resistance when in gear (clutch pressed in). Is it normal ?

I changed my handle bar last night and ran into the same issue. I am doing something wrong, it being a nightmare.