XJ11 Clutch issue

[koehlerk]

Hi all. I've been having clutch slip so I replaced the clutch cable, and followed TopCat's tech tip on replacing plates, springs and adding extra steel. After I had the thing back together, I adjusted the clutch as the manual suggests including proper play at the lever less than 5mm. This is where the issue comes in. If I pull the lever all the way in hard (like I would do when shifting while riding) while in first gear, the bike pulls forward. If I let out a little, I have no pull until I let out more (like I would when starting from a standstill). I've adjusted the clutch as many ways as I can think of with no luck alleviating this problem. It's either pulling, or the clutch won't engage at all.

Did the extra steel mess me up, or am I doing something wrong here?

Suggestions? Thanks!

-Kirk

[mro]

or am I doing something wrong here?

I've put the extra steel plate in several bikes and not had a problem.

If you have about 3/16 inch free play on the clutch lever (handle bar) and there's free play on the clutch lever inside the case, and the adjustment (inside case) is correct.........

You should not have a problem.
Might double check clutch adjustment, (start inside case)

then check that clutch cable is routed "ok", not getting pulled or binding somewhere between handle bars, fraim and over engine.


mro

[pggg]

koeh, get the motor nice and hot and give the bike a good thrashing out on the road, then adjust the cable. The new replacement cable is the right length?

[mro]

just had a thought

When you open case,
check that the 3 steel balls are in posistion on the push screw housing/ball retainer


mro