Clutch lever very tight

[Dgormley]

Spargett, check the other end of the clutch push rod for an extra #10 ball. I had the same problems as you with my CL. The previous owner had put a ball on the other end as well as one in the lifter piece! The sidecase would not go on. I beat my brains out trying to figure it out. I finally looked down the shaft with a flashlight and saw it. Got it out with sticky gasket cement on the end of the clutch pushrod. Weird deal, but give it a shot..............................D Also, that clutch lifter needs to ride lower or the geometry wont be right.

[Spargett]

Ooh, interesting. Can't wait to check that tomorrow. I had about the same feeling when I realized the case wasn't shutting with bearing, "You've got to be kidding me". Hah. Hopefully that explains it.

Spargett, check the other end of the clutch push rod for an extra #10 ball. I had the same problems as you with my CL. The previous owner had put a ball on the other end as well as one in the lifter piece! The sidecase would not go on. I beat my brains out trying to figure it out. I finally looked down the shaft with a flashlight and saw it. Got it out with sticky gasket cement on the end of the clutch pushrod. Weird deal, but give it a shot..............................D Also, that clutch lifter needs to ride lower or the geometry wont be right.

[davomoto]

Scott, back of the clutch adjuster thread when you install the cover. Once installed, turn adjuter in until you have about 1/2 of freeplay at lever. The final adjustments at cable ends.

davomoto

[Spargett]

I have never been able to get the clutch adjust to move whatsoever. I ended up taking it off today and having to hammer it out it was so tight. No obvious reasons for it sticking. The metal was clean and smooth. Appeared to just be a poor fit somehow. I cleaned it up further, and lubed the outside with some assembly grease. Had to hammer it back in. Still just as impossible to move around.

I also noticed two corresponding holes inside of the adjuster that aligned with a grease nipple on the crankcase to lube the inside of the adjuster where the thread is housed. Which made me wonder, how could this work if one is turning the housing and un-aligning these grease ports?

Scott, back of the clutch adjuster thread when you install the cover. Once installed, turn adjuter in until you have about 1/2 of freeplay at lever. The final adjustments at cable ends.

davomoto

[Spargett]

I pulled the clutch rod lifter out to to see if there was possibly a 10mm bearing shoved in first, deep on the other side, which could be causing my issue of the case not closing with the bearing in the clutch lifter. Unfortunately I couldn't find one. I was hoping it'd be that easy of a fix.

I then thought, maybe it has been installed facing the wrong direction this whole time? I noticed on the other end there appeared to be the wear of what could have been made from a bearing.

I then dropped the bearing into the clutch lifter and packed everything up again. So tight I couldn't move the lever whatsoever. Tried adjusting the cable free play to no avail.

I tried pulling out the bearing and reattaching with the rod lifter by itself, "reversed" with the groove outwards instead of the round end. This time I couldn't engage the clutch at all. TOO MUCH slack.

Can anyone clear up which way the rod should be facing? I'm beginning to not trust anything about the way the bike came.

P.S. I measured the rod itself. It's about 9.65" long. Is this correct? Does the fact that I have a CL77 right side crankcase require a different length rod? So many questions.

[Spargett]

The biggest issue I'm really having is shifting with the shift lever. Lots of heavy clunky clicks when it is "working", and an incredibly hard time moving to second, which is simply impossible sometimes. I feel like I have the lever on at the right 11 'o clock position. But I just wanted to see if anyone sees anything wrong. Feeling more and more lost on this issue.

[eyhonda]

I measured my rod and it is 9 11/16" (9.6875"). Check the part numbers for that rod between a cl and a cb. If it is different, it could be shorter. The cl cover might be the cause. Again, check part numbers. Maybe a cl owner can measure their rod.