Super hard clutch lever!

[Flaming Chainsaws]

I recently replaced my clutch cable with a brand new one and did a little bit of work to the clutch (tightened gigantic nut). Now it is VERY hard to pull the clutch lever. I can do it but it takes so much energy to do so.

Before I did anything, it was working great. What could be the problem? Maybe I tightened the clutch springs too much? I don't have a torque wrench.

The bike is a 1983 GS1100E with a 1982 GS1100E engine if that matters.

[JEEPRUSTY]

I think the springs can only be so tight and the rest is torquing the bolts so they do not back out.

Did you follow the manual's procedure for adjusting the cable? Didja lube it while you had it all apart. ( to continue the oddly perverse nomenclature so far used. )

[chef1366]

Did you ground out the clutch cover?

[TeamDar]

Jeez kid.....you could **** up a rock fight!

[chef1366]

Clutch springs aren't anything but snug tight. Feel the bolt bottom out and that's it.
See if your clutch cable has an unusual bend in it or you put the arm on the clutch cover on at the wrong angle.

[Stahlgrau333]

Check the inside surface of your clutch basket, where the plates 'ride'. The plates had 'dug in' to soft aluminum basket of mine, and when we went to adjust it, it was damned near impossible to engage it. Swapped it out with a newer basket with a smoother interior surface and that fixed it.

[Flaming Chainsaws]

I have tried adjusting the bolt where it goes into the clutch perch. I have learned that that only controls where the clutch engages/disengages. I tried adjusting at the arm on the clutch lever as well. But it only got even harder.

My clutch basket is in superb condition. This is the only picture I have but you can kind of see where the clutch plates were. NO GROOVES!


I will need to check the clutch springs again. So I only tighten it until it's snug?

Does anyone know how the clutch cable should be routed? Oh wait, I can look at the manual I downloaded from BassCliff's site....

[JEEPRUSTY]

Pic does not show the full basket. Are the splines in the clutch basket smooth all the way in?

If so then that is not an issue. Mine had a lightly polished mark at the point each plate is shouldered but no wear.

[Flaming Chainsaws]

Pic does not show the full basket. Are the splines in the clutch basket smooth all the way in?

If so then that is not an issue. Mine had a lightly polished mark at the point each plate is shouldered but no wear.

Yeah, it's not the best picture but that's all I had on file. I will take another picture when I get back into the clutch. But there are no grooves that I remember.

[Flaming Chainsaws]

Ugh... Someone rated my thread with a 1 star. Seems to be happening a lot lately. Is it something I said?

Anyways, I rerouted the clutch cable according to the factory manual and it's still hard. I don't get it? Maybe my new clutch cable is junk...

[78gs1000]

Ugh... Someone rated my thread with a 1 star. Seems to be happening a lot lately. Is it something I said?

Anyways, I rerouted the clutch cable according to the factory manual and it's still hard. I don't get it? Maybe my new clutch cable is junk...

I gave you 5 starts to offset

[Flaming Chainsaws]

I gave you 5 starts to offset

Ha! lol

But really. A lot of my threads have been getting one stars. Including the GSR patches, my build thread, and more. Someone obviously doesn't like me. Whoever you are, if you have something to say, PM me or something. No sense in rating my threads with a one star.

Anyways, this bike would be near impossible to ride with the stiff clutch lever. I'd end up killing it at every stop. Or maybe a wheelie!

So tomorrow, I'll pull off the clutch cable and check for damage, although it's brand new......

[Souske]

Ha! lol

But really. A lot of my threads have been getting one stars. Including the GSR patches, my build thread, and more. Someone obviously doesn't like me. Whoever you are, if you have something to say, PM me or something.......

Maybe they don't like homosexual chainsaws?
They had to remove the tag feature on another board I frequent, due to build threads getting tagged "bootyfab" pretty sure it was done in jest, but some other members got quite upset.

Please post up if you figure this out, my hand starts to cramp if I hold the clutch in too much

[DCrippa]

I have the same problem but on a 550 ... Wondered if the PO put harder springs in...

[Dodik]

I have the same issue on my 750, once i switched the cable (old on snapped) it became really hard to pull, much harder than my brake lever lol. i went thru everything and found nothing, that would help. its been like that for a bit over a year now and i havent wheeled or stalled due to it, you just build up the strength needed as you ride more. although i do get cramps while in traffic.