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Clutch lever very tight

Clutch, Transmission, Drive Chain, Sprockets
Dgormley
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Clutch

Post by Dgormley » Tue Dec 08, 2009 11:52 pm

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
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Re: Clutch

Post by Spargett » Wed Dec 09, 2009 12:37 am

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.
Dgormley wrote: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.

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davomoto
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Post by davomoto » Wed Dec 09, 2009 6:02 pm

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
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Post by Spargett » Wed Dec 09, 2009 8:20 pm

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?
davomoto wrote: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
Attachments
You can see one of the holes here that leads to a grease nipple.
You can see one of the holes here that leads to a grease nipple.
And the corresponding hole in the thread adjust body.
And the corresponding hole in the thread adjust body.

Spargett
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Post by Spargett » Wed Dec 09, 2009 8:48 pm

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.
Attachments
It appears that the rounded edge is facing the left crankcase (1). But low res pencil drawings can be up for interpretation.
It appears that the rounded edge is facing the left crankcase (1). But low res pencil drawings can be up for interpretation.
Rod reversed from original position.
Rod reversed from original position.
Last edited by Spargett on Wed Dec 09, 2009 9:10 pm, edited 3 times in total.

Spargett
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Post by Spargett » Wed Dec 09, 2009 9:03 pm

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.
Attachments
IMG_7011_1067x800.shkl.JPG

eyhonda
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Post by eyhonda » Wed Dec 09, 2009 10:23 pm

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.
63 cb77 cafe
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