Question about 2004 Suzuki VL 800 Volusia

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Snapped and then replaced the clutch cable. Adjusted it all the way in and then slowly out trying to find the right spot to engage the gears. Have only been able to get 1st, N & 2nd gear. It will not go into 3-5. Double checked to make sure that the cable was routed the same way it was originally. What am I doing wrong.

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  • Suzuki Master
  • 40,868 Answers

Hi Mark, a proper clutch adjustment for big twins starts by squirting some silicone spray or Brake Kleen into the top of the rubber boot on the clutch cable and sliding it upward exposing the cable adjuster. Loosen the jam nut and turn the adjusting screw in until light resistance is felt against the clutch rod then back the adjusting screw out 3/4 of a turn and tighten the jam nut. Check primary fluid level and replace derby cover. Go back to the clutch cable adjuster and back it out until there is 1/8" free play between the clutch lever and the bracket perch. This is correctly accomplished by pulling the clutch cable end outward with your right hand and pulling the clutch lever in with your left hand and modest pressure on both hands to eyeball the free play. Tighten cable adjuster jam nut and slide rubber boot back to it's original position. On Sportster models, the procedure is the same except the clutch cable adjuster screws directly into the primary cover with a jam nut. For more information about your issue, please visit the websites below. Good luck and have a nice day.
2004 Suzuki Motorcycle Service Repair Workshop Manuals
Suzuki VS 800 S50 Boulevard Clutch Change
Delboy Garage Harley Sportster Clutch Adjustment

Posted on Oct 06, 2015

6 Suggested Answers

6ya6ya
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Posted on Jan 02, 2017

  • 1 Answer

SOURCE: knocking noise when clutch engaged

also taking off outer cover and checking that the bots holding the clutch are all tight wouldnt hurt

Posted on Feb 11, 2009

rockitman187
  • 2559 Answers

SOURCE: Bike turns off when I put in 1st or 2nd gear

First replace the clutch,clutch basket,and throw out bearing that has been destroyed,check the cable for damage and if you still have the same problem,Then check the kick stand switch.

Posted on May 20, 2009

  • 8404 Answers

SOURCE: gear disengaged on 2nd gear

You probably will not like the advice that comes with what I suspect is the answer to your question.

My friend, let this be a lesson for you ... keep your wheels on the ground. I think you have stripped second gear
and suspect this will be a very expensive lesson for you.
You have a 17 year old motorcycle, it needs more respect from you, not a beating.

Treat your machine with respect and make it easy for we other motorcyclists to show we are good citizens. Not good to scare women and children and horses.

Thank you for posting your question on FixYa.com

please vote

a

Posted on Nov 11, 2009

  • 76 Answers

SOURCE: 1992 Suzuki Intruder Clutch problem

THE CLUTCH PLATES COULD BE WORN ALSO THERE ARE ADJUSTMENTS BY THE CLUTCH LEVER TURN IT COUNTER CLOCK WISE TO TAKE SLACK OUT OF THE CLUTCH CABLE

Posted on Jan 29, 2010

  • 46 Answers

SOURCE: Dirt Bike Shifting gears problem(1972 yamaha dt 250 2stroke)

it will be down to adjustment, there are 2 ways to adjust one close to the engine casing and one at the lever just have to get a good balance :)

Posted on Apr 11, 2010

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ADJUSTMENT

Free-Play See Figures 8, 9 and 10
The clutch free-play is adjusted automatically by a built-in clutch control mechanism. This device allows the clutch controls to self-adjust during normal operation.
The system consists of a spring-loaded gear quadrant, a spring-loaded pawl and a clutch cable which is spring-loaded to preload the release lever bearing. This compensates for movement of the release lever, as the clutch disc wears. The pawl, located at the top of the clutch pedal, engages the gear quadrant when the clutch pedal is depressed and pulls the cable through its continuously adjusted stroke. Clutch cable adjustments are not required because of this feature.
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Fig. Fig. 8: Clutch self-adjusting system component identification for the 3.8L engine


CHECKING ADJUSTMENT
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