Out of clutch adjustment
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  1. #1
    Newbie
    My Bike(s)
    Suzuki GS500 (2007)
    Posts
    11

    Out of clutch adjustment

    Hey Guys,

    Pretty stuck here (2007 GS500, 36*** km).

    I'm completely out of clutch adjustment.
    The pushrod adjustment is all the way in, clutch lever adjustment all the way out, and adjuster above sprocket cover is all the way out.

    Lever is slack. Any ideas?

    Thanks,
    Peter

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  3. #2
    Super Moderator

    My Bike(s)
    Vulcan 900, Can-AM Spyder
    Location
    Ocala, FL
    Posts
    11,028
    Is this a hydraulic system or cable operated ?

    If cable, the cable may be stretched.......and about to break.

    If hydraulic, it's probably time to flush and bleed the lines; but it may be a sign of a bad cylinder at either end.
    If one cylinder is bad, I would replace both.
    Don't believe everything that you think.

  4. #3
    Newbie
    My Bike(s)
    Suzuki GS500 (2007)
    Posts
    11
    Sorry, its cable operated.

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  6. #4
    Found second gear by accident
    My Bike(s)
    2014 Honda Valkyrie
    Location
    atlanta, ga
    Posts
    326
    Clutch cables are supposed to be inspected for wear, and lubed, roughly every 3k-4k miles. Probably a good idea to do it at every oil change. They do stretch over time and you may also see some fraying near the connection points. Replacing it now sounds like a good first step.

  7. #5
    Super Moderator

    My Bike(s)
    Vulcan 900, Can-AM Spyder
    Location
    Ocala, FL
    Posts
    11,028
    And after noting the statement about the lever (and I assume the cable and other parts too) being "slack"........there may be something broken inside the clutch.
    They most often stick closed......not open.
    Don't believe everything that you think.

  8. #6
    Newbie
    My Bike(s)
    Suzuki GS500 (2007)
    Posts
    11
    Okay thanks guys, just ordered acable. I'll let you know what happens. Hope its not the clutch

  9. #7
    Newbie
    My Bike(s)
    Suzuki GS500 (2007)
    Posts
    11
    Okay so I replaced the cable and still no luck, everything maxes it out and there is still no tension in the lever. Should I start opening the clutch up?

  10. #8
    M-J Lifetime Achievement Award
    My Bike(s)
    Yamaha MT09
    Location
    Perth WA
    Posts
    6,194
    Sounds like the actuating mechanism needs attention...or the clutch springs are weak. Inspection is going to be the only way you can find out. How is the clutch itself working? presumably the bike would be hard, if not impossible to get into gear?
    Smoke me a kipper I'll be home in time for breakfast

  11. #9
    Newbie
    My Bike(s)
    Suzuki GS500 (2007)
    Posts
    11
    Yeah it's stuck in neutral and forces itself back into neutral when I try and change gears with the bike running. When the bike is off it shifts without the clutch of course.

    I'm going to open up the clutch tomorrow and I'll you fill you in on what I see.

  12. #10
    M-J Lifetime Achievement Award
    My Bike(s)
    Yamaha MT09
    Location
    Perth WA
    Posts
    6,194
    Sounds like the clutch is not separating from what you describe. I would hazard a guess the spindle on the actuating arm isnt in the correct position or has failed in some way. I would expect the bike to clunk into gear then leap forward before stalling if the clutch were working at all.

    Is the arm on the actuating spindle...the one above the case...tight....and not spinning round?
    Smoke me a kipper I'll be home in time for breakfast

  13. #11
    Newbie
    My Bike(s)
    Suzuki GS500 (2007)
    Posts
    11
    I'll go check that out later today. I opened up the clutch and did not see anything obviously wrong with it. The friction disks aren't warped but they are black and have little red dots which look like possible wear.

  14. #12
    M-J Lifetime Achievement Award
    My Bike(s)
    Yamaha MT09
    Location
    Perth WA
    Posts
    6,194
    Possible wear indicators and its the plain plates that need checking for warping. I would suspect the actuating mechanism...esp the arm to rod tightness.
    Smoke me a kipper I'll be home in time for breakfast

  15. #13
    Newbie
    My Bike(s)
    Suzuki GS500 (2007)
    Posts
    11
    I can't find the actuating mechanism you're talking about. Is it outside of the crankcase and is there any chance you could send me a link to a diagram or photo? I agree that it doesn't seem like the clutch plates are the problem.

    Sorry for the slow progress updates, my bikes in a friends garage across town and I can only make it over every couple of days.

    Here's a photo I found online of the GS500 crankcase: https://www.google.ca/url?sa=i&rct=j...93878884039132

  16. #14
    M-J Lifetime Achievement Award
    My Bike(s)
    Yamaha MT09
    Location
    Perth WA
    Posts
    6,194
    https://www.cmsnl.com/suzuki-gs500f-...026/partslist/ I googled 07 GS500 clutch parts fiche and this is what came up. The actuator is actually under the outer cover and appears to have an adjuster screw to take up any slack between the clutch push rod and the actuator face.

    This is listed as a GS500(F) which I would guess runs the same clutch and is just a faired version.

    Good luck...

    PS the actuator appears to be the quick thread or ball and ramp type whereby a metal disc rides up a thread or ramp and presses against the clutch push rod thereby separating the clutch plates. It seems to have an adjuster bolt down the centre to allow fine adjustment of the pack separation
    Last edited by Aussie Steve; 05-03-2017 at 05:09 AM.
    Smoke me a kipper I'll be home in time for breakfast

  17. #15
    Newbie
    My Bike(s)
    Suzuki GS500 (2007)
    Posts
    11
    Okay thanks man, you've been a huge help!


 

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