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Replaced snapped clutch cable and adjusted, clutch won't disengage

Started by DesertFox, July 30, 2014, 05:13:21 PM

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DesertFox

Unfortunate that my first post on this board has to be a cry for help...so I guess I'll do a really quick intro:  Hi, my name is Cory.  I'm a 2nd year rider with a '97 GS500e, loving every minute of riding in the beautiful Pacific Northwest, specifically the Seattle area (or for you folks who are familiar with the area, I'm in Bremerton :)).

So, on to the issue that's keeping me from enjoying this awesome weather.  A little over a week ago my clutch cable snapped right at the base (on the clutch side, don't know the technical term).  I removed this one and replaced it with a brand new OEM cable yesterday...followed the instructions in this post: http://gstwins.com/gsboard/index.php?topic=20468.msg191920#msg191920

I turned the pushrod adjustment screw until I met some resistance and backed off about 1/2 turn, adjustment the other two spots until the clutch level felt solid but had a little bit of free play.  At this point everything seems to be going smooth.  With the bike on the center stand I shifted into 1st gear and pulled in the clutch lever then spun the wheel by hand.  Not budging.  If I give it enough force I can turn the motor over with the wheel...so it's as if the clutch will not disengage.  I have adjusted everything multiple times but no joy.  If I start up the bike and shift into any gear it will start turning the wheel over.

What could be wrong?  The bike shifts smoothly into any gear and rolls freely in neutral.  Is something in a bind from the sudden cable snap?  I was in 1st gear when it died and it came to a pretty violent, grinding hault even though I was moving very slowly in a parking lot.

Any input would be much appreciated...or if you have links to a good article on some next steps.  I've searched the forums as well as Google but haven't come up with anyone encountering this issue...unless I'm just using the wrong verbiage.  Thanks!

gsJack

Try setting it up following the procedure in the shop manual:

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

If it worked OK before the cable snapped it should work with a new cable properly adjusted.
407,400 miles in 30 years for 13,580 miles/year average.  Started riding 7/21/84 and hung up helmet 8/31/14.

DesertFox

Thanks for the quick response!  I have the manual and followed that procedure as well after the first time didn't work.  Didn't seem to make any difference.

I did just come across this post http://gstwins.com/gsboard/index.php?topic=66489.msg800342#msg800342.  I guess I should rule out this possibility.

and this one... http://gstwins.com/gsboard/index.php?topic=63895.msg759452#msg759452 ....man, how did I miss these yesterday?  Must have been too enraged  :mad: 

It's probably due for an oil change anyway.

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