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replacing clutch lever

Started by chister, October 07, 2004, 03:10:52 PM

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chister

Well it was bound to happen one day...forgot to remove the lock on the front wheel and starting off I laid it on the ground :x
No a big deal, a little scratched here an there :(
But the clutch lever broke. Anyone know how to change this? What are the necessary tools :dunno:

Kerry

Quote from: chisterthe clutch lever broke. Anyone know how to change this? What are the necessary tools :dunno:
Let's see:
    * An open-end wrench to supply some slack at the lower end of the clutch cable (10 mm, I
think).  Count the turns so you can restore it to the same position:


* Fingers, to provide additional slack at the lever end of the clutch cable:


* A large flathead screwdriver and a 10mm (I think) socket wrench to remove the pivot pin from the lever itself.

* A small-to-medium Phillips screwdriver to remove the clutch switch, so you don't BREAK it by yanking on the lever when you think it's stuck.
[/list:u]I don't know if you would consider it a tool, but some general purpose grease to smear on the contact surfaces is also a good idea.
Yellow 1999 GS500E
Kerry's Suzuki GS500 Page

scratch

Tools: Two 10mm wrenches (or one wrench, one socket and driver) and one 12mm wrench (socket wont do in this case).

1st loosen the clutch cable adjuster on top of the leftside crankcase, by loosening the locknut with the 12mm open end wrench (see, I told ya a socket wont work) and screwing down the adjuster all the way.

2nd: Remove the nut and bolt holding the lever.

3rd: loosen the lockring on the clutch cable adjuster at the handlebar and screw in that adjuster all the way in toward the lever, but match up the slots to remove the lever with the cable.

4th: swap levers

5: put things back, adjusting the crankcase mounted adjuster first to obtain the 4mm of slack between the forward edge of the lever and lever mount, and then adjust the cable adjuster at the handlebar to taste (where you want the friction zone, or where the clutch engages/disengages).

6.  :)
The motorcycle is no longer the hobby, the skill has become the hobby.

Power does not compare to skill.  What good is power without the skill to use it?

QuoteOriginally posted by Wintermute on BayAreaRidersForum.com
good judgement trumps good skills every time.

manofthefield

Quote from: Kerry* A small-to-medium Phillips screwdriver to remove the clutch switch, so you don't BREAK it by yanking on the lever when you think it's stuck.
This one sounds familiar  :roll: :smacks head:  Oh well, live and learn
motorcycleless
1998 GS500E sold 6/20/11

chister

thanks for the help, fixed it in the workplace parking lot, and as always enjoyed the ride home  8)

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