Question about Suzuki GSX 600 F (Katana Motorcycles

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95 gsx600 katana. I missed a couple of gears while attempting to engage clutch while shifting. Now clutch is loose-fully( no tension felt at all), bike idles in neutral but shuts off when put into gear, bike was noticibly running hotter than normal( usually not hot or just usual engine heat) what can you make of these details?

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If it shuts down when putting in gear I think the clutch cable itself may be broken or the activating pin inside the engine. First off. Test the cable. Locate the clutch on the bike. Right hand side of the engine.On the top of the engine casing but to the right hand side is a lever connected to the clutch cable. Pulling the clutch lever on the handle bar should cause this lever to move. If it does not the cable is broken or needs adjustment.
Replacement is pretty straightforward. Unscrew it at the engine casing. Then unclip it from the lever by pulling the cable away from the lever then forward so it comes out of the groove and then down. Take note of the cable routing so that when you replace it goes back the same way. You may need to remove the fairing and tank.
If the cable tests fine you will need to open the clutch casing.Let me know if you need more help

Posted on Jul 17, 2010

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  • suthernoracl Jul 17, 2010

    Thank you for the response. I forgot to mention the harsh grinding sound I heard while missing the gears. Now with that said do you still think it's the cable. I assume it maybe the spring due to the lack of tension in the clutch lever. Then again I'm no expert. Any final thoughts. Where can find a clutch cable?

  • Rene Rossouw
    Rene Rossouw Jul 17, 2010

    I hope you mean at which shop. :-p
    Any of the biking accessories stores should be able to supply one and they're not that expensive either. I'm in South Africa and in my town we even have a store that can make any type of control cable if you give them the original sheath but they're a bit pricey. Agents should be able to help you but at a premium and be prepared to wait 6 weeks or so for shipping.

    The tension that you (should) feel on the lever is the springs inside the casing. These springs force the clutch and pressure plates together to effect a coupling that drives the gearbox. If the cable is broken then no tension. The grinding is the gear teeth crashing against each other since the "engine side" of the gearbox's gears are rotating and the "chain side" of the gearbox is stationary. When you pull in the clutch lever the engine is totally disconnected from the gearbox and the "engine side" of the gearbox stops rotating, thereby enabling the gears to mesh. (When riding the same thing happens because even though the chain side of the gearbox is rotating now, its speed is not matched to that of the engine)

    FYI - With some skill you can still drive the bike without a clutch (if you can get it going) as long as you never have to stop. :-o Definately not recommended though.
    Let me know how the testing of the cable went.

  • suthernoracl Jul 18, 2010

    After removing the fairings, accessing the clutch cable. The long screw that's inside the cover was almost completely out. I tightened it back into cover and tweaking the fine adjuster on the handle as well I was able to recover some tension in the clutch lever. However, it still continues to shut off once the gear is engaged. I'll resume my search later this week, just wanted to update you. Thanks for your input on this situation, its greatly appreciated.

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