Clutch

[rdcjohn]

I installed new levers and clutch cable tonight and the clutch is super hard to pull in. I never remember a bike ever this hard even riding my dads big 2 strokes growing up. Any advice? When I bought it, it had a white bros easy clutch mechanism on the cable but it was beat up so I did away with it.

[teamgreen500]

Somebody, in all their wisdom, may have installed some heavy clutch springs?

Manny

[mikesmith]

Cable routing,lubing the cable(even if its new), extending the clutch arm,running a CR type lever positioned for most leverage made mine pull lighter than some 250's.

[rdcjohn]

I have got bigger issues now, No matter how much I adjusted the cable it would not release the rear wheel with it in 1st gear and me pushing it back and forth in the garage.. I have no clue what is going on now, I adjusted both adjusters to the max then back down slowly.

[mikesmith]

Did the clutch work before you removed the "easy clutch"?Maybe the "easy clutch" gave you a little more adjustment on a almost worn out clutch,by removing it you dont have enough adjustment left.Try it with it on,most likely your clutch is shot and that just helped squeeze the last bit of life out of it.

[kawdude]

How about putting some vicegrips on the lever in front of the sprocket and see if that makes the clutch engage.  If it does then you know where the problem lies...

[rdcjohn]

Here is another question now. Should I be able to put it in first gear and pull the clutch and have it push around as if it was in nuetral or should it be very difficult to push and sound like I am trying to jump it?

[mikesmith]

Mine has some drag in first gear with the clutch in,but if I push it or coast down a hill its not going to turn the engine over.It's not going to freewheel like neutral or not in gear.

[Rick]

You don't want to rely on just pulling in the clutch with the engine not running as the diagnosis, as the clutch plates will stick together with the engine off after the clutch pack has been release by pulling in the clutch.  You'll have to start her up to check on to see if the clutch pack is releaseing.  

The other advise on getting a smooth clutch pull is correct.  I use a Fly adjustable lever, as it has a Honda ratio and bearings in the pivot.  With the Fly lever and stock clutch cable, no modifications to the clutch arm are required.

Good luck

Rick

[Sharc]

Sounds cool.. Where do you get Fly perch/levers...?

Sharc

[gwcrim]

I'm not saying this is the culprit, but did you thoroughly lube your new cable?

[rdcjohn]

What should I lube it with? Thank you for all of your help. The bike is officially back together. I just need to ride it now. I will try and get a pic

[mikesmith]

Rocky Mtn has a cable luber for $12.99 and lube for $4.59.Or use a can of Tri-Flow,elevate the end of the disconnected cable,make a funnel out of tape, fill it with lube and let gravity do its thing.You can get a adjustable lever/perch from Fly Racing,Works Connection or Pro Circuit,be leary of the cheaper lever.My pivot bolt for the lever bearing must be made of butter!Veary cheap!.Why not lengthen the lever for no money and a little work,unless you have to pay a welder. And even then?

[Rick]

Yup, the cheaper Fly lever with the little spring steel piece that engages the adjuster is not the right ticket.  The lever that uses the ball bearings in the adjuster is the right lever.  However, you must remove the allen screws and add loctite, as these little guys will back out drop the spring and ball on the ground.

Rick

[gwcrim]

I just dangle mine from the ceiling and drip motor oil down in over the course of a few days.