I put in a new adjustable clutch lever I got today, the problem is that in settings 1 - 3, with the clutch in, the bike will NOT start. I have to choose settings 4 - 6 for it to start.

It feels like it hits the handlebar grips too early and therefore not pushing in the clutch switch to allow the bike to start. Settings 4 - 6 starts fine (since it goes out further)

What should I do?

Also, I'm trying to correctly adjust the clutch cable tension, and in the manual here:

http://www.gs500.net/gallery/data/500/GS500_clutch_adjustment.jpg

I do not know how to loosen (5) the "locknut" - how do I do that?

Have you tried the wiki, there are better pics to help understand that area. its under adjustment clutch or front sprocket cover, something like that.  Its just a nut you loosen and adjust the screw in the middle.

http://wiki.gstwins.com/index.php?n=Maintenance.RoutineMaintenance

When I tried loosening it, that entire assembly pushed in, is that normal? It was under a lot of tension, so I didn't want to try loosenin it anymore.

Unless the screws securing the mechanism on ther other side of the cover are loose or missing, i dont think that should happen.  Your cable tension may be way off.  Have you followed the procedure for taking all the tension off the cable before adjusting the push rod?

I agree with making sure the cable is slack and @ the 1/4-1/2 adjustment part..1/4 is plenty, going to 1/2 makes the release mechanism rotate more  before it contacts the pushrod. The locknut requires a 10mm socket or open end with the correct offset IIRC.

"When I tried loosening it, that entire assembly pushed in"  That is how it works, CCW is the same way it goes when you pull in the lever at the bars, CCW and inward pushes in the pushrod, that then releases the clutch.

What lever and perch did you install?
Only the LSL lever is compatible without changing the perch and they are 100% compatible.
Pictures? Part/model numbers?

adidasguy...

So many cats, so few recipes.

Quote from: the mole on November 30, 2013, 02:09:41 PM
So many cats, so few recipes.

I like kitten cause it tastes like chicken 

Quote from: adidasguy on November 30, 2013, 11:02:34 AM
What lever and perch did you install?
Only the LSL lever is compatible without changing the perch and they are 100% compatible.
Pictures? Part/model numbers?

2001 SV650 Clutch Perch, the lever was an eBay bought lever for the SV650. One of those Chinese types. It seems to be pretty good quality though, nice and sturdy.

I adjusted it now, it feels good to me. Settings 4 - 6 is not that ideal as the clutch starts engaging a bit further out. Settings 1 - 3 is nice because it engages closer (for me anyway), I keep it at 3.

However it still will NOT start in settings 1 - 3, not a huge problem I guess since I just have to switch from 4 to 3, but I would still like to rectify it, if anyone has any ideas?

If anyone is in the Sydney area and can help me out with checking if I have done everything right, please let me know!! I will come to you!

There is an easy way to solve this problem, you just pull the connectors off the clutch lever switch and connect them together.
You can buy two male spade connectors and crimp them on each end of a short piece of wire, then plug them into the connectors on the bike, this easily reversible. Or you could just cut off the existing connectors, bare the wires, solder them together and insulate the joint. This will let you start the bike with the clutch at any setting, pulled in or not.
If you do this, it is possible to start the bike in gear with the clutch engaged, so don't.

Yea, the thought of by-passing the switch altogether crossed my mind. However looking at the switch now, it seems that with settings 1 - 3, it just doesn't touch the connectors as I initially suspected, so I might just try and put a dab of solder to extend the connection a bit.