Stiff Clutch problem

[digitalsam]

Alrighty. Since the rebuild, the clutch has been very stiff. It requires some pull, much more than before and much more than any of the other bikes in the neighborhood. Ya'll suggested I lube the cable. It seemed to help a tiny bit, but not tremendously.

The problem seems to be under the cover. The lever under the cover is very hard to pull. I am afarid that it will bend or break.

Why would it be so hard to move? I cannot lift it by hand, it takes too much force.

Here is an image I stole from a post by 81xsproject, The lever is off in the photo, but that is the lever that is so hard to lift.

[digitalsam]

I think I posted this in the wrong section. Can someone move it? Sorry.

[randy]

Make sure you cable is not kinked or making sharp bends. That lever is supposed to be too hard to lift by hand, it's an indication that your springs are in good shape. In my experience, even using a lever (screwdriver) it's a bit stiff.

[jmnjrpa]

Don't

know if this condition is as the pic but the screw ought to extend past the nut somewhat. with the screw engaged that deeply I would think something is wrong.

[DGXSER]

Yep, that lever should not be something you can grab and move by hand, unless your a human torque wrench!!

I would also suggest you look at the clutch cable routing for kinks or sharp bends. Did you replace the springs? perhaps someone put some REALLY heavy duty springs in there on you.

[DiverRay]

I would also think the cable routing may be the problem. Check for nice WIDE bends on the cable as it goes from the left handlebar to the cover. If it's the same 30 year old cable that has been on the bike since new, I would also think about a replacement. I did have one cable that was hard to use, as it was just beginning to come apart inside the housing.

[trbig]

...but the screw ought to extend past the nut somewhat. with the screw engaged that deeply I would think something is wrong.

I don't think it has anything to do with his problem, but that isn't the stock nut that goes there. That one's much thicker.

Sort of just reaffirming others... with the cable off the lever on the bars, does the clutch lever move free and easy with no binding? With the cable disconnected at both ends, does it slide EXTREMELY smooth and easy back and forth inside the shielding? If the answer is yes to those, then the problem is in the clutch.

That being said, if you're comparing your clutch to a modern bike with possibly a hydraulic clutch, there'll be no comparison.


Tod