clutch issues....

[airborneXS]

So I replaced my clutch cable with a spare provided by some members because the old one snapped, and when i installed the new one it seems that there is NO free play even with the adjuster on the handlebar tightened all the way in. I put the bike on the center stand to test the operation, and this is what i found:
1. the lever is super tight, there is no free play at all.
2. when i pull the lever in, i can shift in to first and the wheel starts spinning as soon as the lever is pulled. if i let the lever out, the wheel stops spinning and even if i give it some gas, the wheel doesnt move

any ideas gurus?

[bikerphil]

The adjustment at the handlebars is adjustment for cable slack, the main clutch adjustment is done at the engine as follows...

http://www.xs11.com/forum/showthread.php?t=140

[cywelchjr]

Even given the fact that the adjustment at the lever is for free play, something sounds fishy as it sounds like it's working backwards, like something might have gotten out of place when the old cable snapped. However going through the adjustment procedure should make it clear if things are working correctly, also make sure that the cable is both routed correctly and hooked up correctly at the bottom.

[airborneXS]

went through the adjustment procedure...nothing....so im guessing i should take off the clutch cover and inspect the clutch?

[Rasputin]

If you are certain that you have followed the proper adjustment procedure then you will haev to pull the clutch cover off. There are retainer balls in the adjuster that can get dislodged. Are you certain you have the correct cable as you may not be able to adjust it if that is slightly different. IIRC the specials and the standards have a different clutch cable, but alas I am getting to the point where CRAFT is taking over my mind.
If you put the bike on it's sidestand you do not even have to drain the oil to take the cover off. Yamabond or the Right Stuff will be more than sufficient for a gasket in case you are worried about ruining yours during removal.
Besides you then get to check plates, frictions etc if you decide to go even further. If you do take the star plate off however be very careful and follow the manual.

[airborneXS]

im not sure what cable i got. it was given to me by a member on this site
....

[airborneXS]

so i got the cover off and it appears that the little balls never got dislodged....what do i check now? any body got any ideas? how can i tell if the difference between the standard and special clutch cable?

[Rasputin]

I am not certain there is a difference between cables. I was hoping someone who knew for sure would chime in here. I could just have faulty memory here. I guess some searching is in order but I have no time tonight...sorry.

[airborneXS]

not to worry rasputin...ur numerous posts have helped me in the past...u are given a pass, but just this once!

[Rasputin]

Did some searching and found that all of the XS fiches show the very same number for all models. Curiously some show (1250mm) after the part number, so that may be where my confusion kicked in. It could also be the part numbers for my XJ are different than XS when it comes to clutch cables. Either way it would appear that I was in error when I said they may be different lengths. Sorry about that.

[TopCatGr58]

Okay, clutch working properly until cable snapped, put on new/used one, now too tight? Did you lube the cable prior to putting it on? How did you route the new cable, any tight bends?

You've gone ahead and removed the clutch housing, found the throwout balls still in their retainer. Good time to regrease them as well as the surface of the throw out bearing and contact surface of the throwout lever.

Have you seen the clutch tech tips to view how and what position the lever should be in with the cable attached. There is a shoulder on the sleeve of the cable, is it all the way into the housing? Same for shoulder of cable at handlebar adjuster. The adjuster at the engine can be difficult to feel sometimes, sounds like you have it adjusted too far IN so that it's keeping the clutch plates separated, not allowing them to come together/contact/grab! Unlock and unscrew the adjuster rod quite a bit using just a couple of fingers on the screwdriver. For that matter, take it all the way out, clean it with a brush, and then lightly grease/lube the threads where it screws into the adjuster piece, make sure the lock nut is way loose and then with 2 fingers turn the adjuster in until it just seats, but with the now cleaned and lubed adjuster rod, you should be able to tell the level of resistance better, I'm thinking you had difficulty sensing when it was just making contact. And then back out 1/4 turn and HOLD it in position with the screwdriver while you set the lock nut! When done there should be just a few mm's of play/travel in the throwout clutch cable lever arm before it gets tight. HTH!?

T.C.

[airborneXS]

im going to try that right now...

[dpotter58]

I sent him the cable, it was a new spare for my lh and should be A-OK. Hope it works but if it doesn't I'm glad I didn't find out on the road because it was always in the tool bag when I traveled just in case Sorry bro, hope things work out...

[airborneXS]

so apparently there are 2 different cables....the specials use a shorter one...i was supplied 2 cables from 2 different members, one was a little longer than the other....originally i didnt check this out, so i removed the cable, checked the lengths, and one was a little shorter...i installed the shorter on, cleaned the adjustment screw, and everything seems to operate correctly...i am now just waiting on the rtv to dry before testing it...i will let yall know...

[Rasputin]

I will be very interested to know as I could have swore there was more than one length. Once I checked the fiches though I was convinced there was only one. Now I am confused again. Such is my life, just ask my wife...lol.