Clutch Adjustment Help!

[staz79]

Yesterday when riding home from work, I came to a fairly sudden stop at a changing light and I felt a bigger than normal clunk as I shifted down to 1st.  I didn't think too much of it until I pulled into a parking lot a short time later and noticed that the clutch didn't seem to be fully engaging...ignition off, in 1st gear with the clutch pulled all the way in, but the back wheel didn't want to turn freely.

I was able to get the bike home (with the only trouble being some resistance shifting from neutral to 1st at one stop light) and left the bike in the garage for a few minutes.  When I went back out to start clutch adjustment, the engagement problem was even worse than before and it felt like the clutch wasn't engaging at all.

I made the adjustment (at handlebar, top of side cover and at push rod screw) using the techniques I read on this forum, but it didn't make any difference with the clutch engagement.  I tried again - same results.  I took the side cover off to make sure the spring mechanism was working.  Spring mechanism seemed ok, but I noticed there was a lot of side-to-side play in the pushrod, but no movement forward (into the clutch).  This is the first time I've ever been working with this area of the bike, so does this sound normal?  It almost seemed to me like there was a missing tension clip or something.

Lastly, frustrated I buttoned everything back up and *snap*...clutch cable snapped.  So, I know I have to replace the clutch cable.  My concern is that there's also an issue with the clutch itself due to the sudden change in behavior and the freeplay in that pushrod.

Thoughts?

[jestercinti]

Try this link.  I think it will help.  I did this a while back on my 82 (essentially similar) and is not bad:  http://gstwins.com/gsboard/index.php?topic=20468.0

[staz79]

Thanks for the link Jester.

When reinserting the clutch push rod, should it just be slid in until it stops?  Should it feel like it's stopping against a hard surface, or should there be some springiness there?  I have the Haynes manual, but it doesn't seem to give much detail.

[jestercinti]

No problem.  We are here to help!

Just slide it in until it stops.  The clutch cable attaches to a screw gear that essentially pushes the rod to engage and disengage the clutch.  It should slide easily.

[staz79]

Alright, new clutch cable is on the way via USPS....I hope that solves my issues.

[bombsquad83]

I think your clutch cable was letting go far before it snapped.  If a few strands of the cable let go before it snapped, that's probably what caused you initial problems.  Replace the cable, and you will be good to go!