Question about 1980 Suzuki GS 750 L

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My mate changed my clutch with a new set,new cable etc.. But its so hard to switch gear,looks like it has not enough pull distance,now after changing the settings a bit its in gear and when pulling the lever it stays in gear..could it be that the plates are in a wrong order inserted? Its a Suzuki 750GS '78..

Posted by Anonymous on


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phil cuzins

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Did you set up the clutch mechanism/pushrod correctly? Where the clutch cable goes into the engine you need to remove the cover to access it. First off, set some freeplay into the cable by either/and adjusting the lower end of the cable or at the lever.
Once done, under the cover you will see a lock nut on the end of a shaft with a slot in it for your screwdriver. Slacken the lock nut. Turn the shaft in (clock wise) until you just feel resistance. Now back it out half a turn. Secure the lock nut ensuring the centre shaft does not turn. Now set the freeplay in the cable to give a few mm's play at the lever (you may be able to acheive this with just the knurled adjuster at the lever end, if not use the inline adjuster at the point where the cable goes into the engine cover). Make sure this is right before the hassle of checking the plates.

Posted on Feb 12, 2011

  • Anonymous Feb 12, 2011

    Hi,thanks for the reply,yes we checked and adjusted the way you describe it but no luck,been told that the plates are not the same and there should be one for the end and first with others in the middle? I never had a bike like this before so i dont know alot about them,its a complete new set with heavy duty springs etc and new cable with mid adjuster,the engine is build in a lowrider chopper frame with Apehanger handlebars etc so custom made cable and forward controls,is there any pics or layout from the clutch on the net where i can see the correct way of inserting the new clutch?

  • phil cuzins
    phil cuzins Feb 13, 2011

    For parts daigrams have a look at this website they should have your engine covered. Failing that, log on to which is a very good forum covering the GS range of bikes. Hope this helps.



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I have a suzuki xl-7 2005 manual and is hard to change gear does this mean the clutch is gone or is there a easy fix

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first off , assume it's a simple easy fix. it can be.
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hard to change gears can mean many things.
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that cause the shifter to do 2 things, its loose as heck and
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you can jackup the rear of car, at the axle place 2 jack stands
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where it doesnt fully engage but I am having the opposite problem where I can not get my clutch to disengage. I have the top cable adjuster-adjusted so there is about a nickels (few mm) worth of play where i can pull the clutch lever that much before the cable really starts pulling. With it on the stand when i start it and put it in gear the wheel spins (enough that it is hard to stop the wheel and if i do the bike stalls) even with the clutch lever pulled all the way in and when riding it, the clutch doesnt actually seem to engage until the lever is almost all the way out. I adjusted the cable adjuster and unscrewed it as far as it can unscrew which was considerably further out then it is with the nickels worth of play and it changed nothing aside from the tightness of the lever/cable. On the stand the wheel still spins and stalls if i put enough force on it to stop the wheel and when riding the clutch still seems to engage and the same point (where the lever is almost all the way out). I think when I am on it and put it in gear, it doesnt stall becuase i keep the Rs up and my weight keeps the back tire from turning and slips the clutch?? Any comments, ideas, advice, etc. would be greatly appreciated. Thanks in advance. ,well , the most obvious is a worn out clutch..BUT it can also be from the plates sticking together, or the springs are beyond their service limit. you can check and change all this at once.... 1) drain the oil 2) take off the clutch cover 3) loosen the screws that hold the pressure plate 4) check the springs (they should be a specific length , over time the length decreases) 5) take out pressure plate 6) check every plate , you can check thickness with a good caliper.( if the pads on the thick discs look worn or are not there the clutch is worn and you need a new set of plates) if they discs are still in good condition try cleaning them with a solvent like alcohol etc...but be carefull you do not use a aggressive solvent as the pads are made from cork and some solvents will damage the cork . If you change the pads the best thing to do is change the metal and the friction pads aswell as the springs. there's a trick to use a clutch that's worn down alot and that is to add another metal plate to the outside so your total stack height becomes higher , however this will only help you 1 or 2 heats after that the clutch is toast either way. hope thats FIXYA.,,,

Gear change no problems for short distances. When the is driven for half hour or more,slowing down changing gears becomes quite difficult. When the is switched off for half hour or more then gear change is...

sounds like to me your clutch is on th way out , try starting your car from cold and put it in second then try and pull off , or when u r driving about 35 mph put in 4th and put ur foot down on gas if it revs but dont go anywhere , when its cold it is taking the strain of the flywheel but as it heats up its starting to slip , u could try adjusting the clutch cable but sounds like u need a new clutch, but always take it 2 a trusted garage and tell them the symptoms and not what u think it is ,let them find the solution hope that helps daz
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