Clutch cable replaced...

[cosmic_splatter]

fixkick,

I replaced my clutch cable today. The old one was a bit gummed up from old grease or something. Here are a couple of questions...

1. I adjusted the clutch so that it grabs about 1/4 from the floor? Is this about right?

2. With the old cable and new cable, I get a slight "clunk" when shifting from 1st to 2nd. Is this normal? 3,4 and 5th are fine. It's only second gear which gives me a bit of clunk no matter how I shift it. It seems better when you are going up hill, then the clunk is not heard as much. Is this normal?

thanks,
John

[fixkick]

set wrong.
the steps are 2 ways, one at pedal and one at bell lever. either works.

my guess is the free play is way too much.
did you see those pages here.
Free play in cable is set to 1/4-1/2 inch , at clutch pedal. using the nut 19,. (CW from end removes play) 1/4 is best.
or at bell lever 1/8" play? 20 to 80 thou,, or about 1/8 inch, 0.125" max.
chapter 7c7
both way show, with stiff cold cable , bottom way works best.

dont give up
do the pedal height tests, if off clutch acts really odd. non linear, oddness, to extreme.....

the real deal.
http://www.acksfaq.com/96-FSM-v1-7C-pdf.htm

[cosmic_splatter]

fixkick,

I did consult the fsm on this job. Unfortunately, both the 95 and 96 FSM show the procedures for the old style cable. Mine is the one with the rubber washer as shown in top photo. The procedures are for the cable with double nut fastening system on the bottom.

http://www.fixkick.com/bbs2/Suzuki-bbs/e...view&id=91

[fixkick]

same free play on all, so the Throw hot bearing does not get overloaded. it dont spin, foot off clutch.
and not too much play or the clutch will not fully release or drags. as his does.