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HELP ! CLUTCH LEVER/CABLE ISSUES!

  1. #1
    Lost in my own mind... 01YZF6's Avatar
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    HELP ! CLUTCH LEVER/CABLE ISSUES!

    so, I am riding home the other day and out of nowhere the clutch lever decides NOT to release itself........ so for the next what felt like 500 miles....I was resorting to manually releasing the lever to engage/disengage the clutch....this really sucked at stop lights !

    so I have the sprocket cover off, the cable released from the lever, and it the spring returns the tension just fine when i pull on the cable.....

    so I lube the cable thoroughly with WD-40, clean out most of the sprocket cover, remove, clean, and reinstall the clutch pushrod engagement ( attached to the cable/spring......it all moves freely and easily....

    hook it all back up and still no return tension on the lever....WTF??

    so i go to the hardware store, buy a new higher tension spring, cut it to fit ( a wee bit smaller than stock for added tension) and it returns the cable ( unhooked from lever) even faster and snappier!

    OK ! so i hook the lever back up to the cable, adjust the tensioner and pull in the lever................


    NOTHING !!! :grrrrrrr ( throws closest wrench into garage door violently)

    any ideas? here are some pics, yes I know it is dirty, and it will be cleaned better after this is resolved !

    TIA !

    clutch lever/spring released open






    clutch lever/ spring pulled in






    The cable snaps back freely when pulled manually when it is not hooked up to the lever.....

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  2. #2
    Lost in my own mind... 01YZF6's Avatar
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    HELP ! CLUTCH LEVER/CABLE ISSUES!

    oh ya click on the pics for larger resolution


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  3. #3
    Lost in my own mind... 01YZF6's Avatar
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    HELP ! CLUTCH LEVER/CABLE ISSUES!

    fixed !

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  4. #4
    Dictionary quoting knob stoinkythepig's Avatar
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    HELP ! CLUTCH LEVER/CABLE ISSUES!

    I seriously doubt the problem is extrernal. Something is messed up inside. The clutch springs inside the engine case are what is supposed to draw the cable back when you release the lever. Since the clutch is engaging, I'd say the springs are OK which makes me think there is something wrong with the mechanism on the inside. Pull the clutch cover off and have a look. Sometimes clutches have spring steel fingers that break off and jam. I hsd this problem on one of my bikes. Made the clutch action very funky.

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  5. #5
    First name on the shit list.... SVRACER01's Avatar
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    HELP ! CLUTCH LEVER/CABLE ISSUES!

    Originally posted by 01YZF6
    fixed !
    was wrong with it

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    When I start my KTM in the morning, rules are broken. Its inevitable...
    01 SV650S (RC51 eater)/07 690SM /03 300EXC/14 XTZ1200
    TRACKS:Firebird/NHMS/VIR/Calabogie/California Speedway/NJMP/MMC/NYST/Palmer/Thompson/Club Motorsports

  6. #6
    Lost in my own mind... 01YZF6's Avatar
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    HELP ! CLUTCH LEVER/CABLE ISSUES!



    I took the clutch lever assembly apart completely and found 2 things wrong......

    The lever itself somehow got cracked at the backside where it is inserted into the lever housing......

    the switch that the lever pushes into was cracked and a small piece of it was lodged........

    put a new lever in and cleaned off the the switch/housing and voila !

    also the lever bolt itself has a nut underneath that somehow got tightened too far, also suspect this helped cause the issue....

    I backed it off a hair and then put a nother nut backed up to it to keep from it loosening up.....

    cleaned and hooked everything back up and the clutch cable is tight and smooth again !

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