Clutch lever REALLY hard to pull!

[joeyplumley]

Bike hasn't ran in a few years... had oil in it though (which I just changed). Replaced sprocket cover and clutch engagement mechanism (linkage). Cable was free and in good shape, new (used) linkage was in good shape too (had to replace it as old one was damaged by the last owner).

Now, it takes almost 2 hands to pull the clutch lever. I've adjusted, at the sprocket cover, max both ways; no better.

Any ideas?

Do I have to drain the oil to take the clutch apart on the right side? Would that help?

[Nessism]

Just a guess but are you sure you got the clutch cover with mechanisim on correctly?

[argonsagas]

It does sound like something has gone out of synch inside, but before you open it why not take a look at the control lever found on top of the casing, and just to the right of the clutch cover.

The cable fastens to this lever and, if it is not at the correct angle, hard pull of the lever can result.

If the pawl inside is not properly positioned, the same result can befall you.

[Nicholaschase29]

sometimes if you replace the cable it makes a world of difference even if it seems to be "free". make sure there are no sharp bends in your existing cable too...

[Steve]

To answer one of your questions...

No, you don't have to drain the oil to open the clutch cover. Just leave the bike on the side stand overnight, and you might get a couple of drops that fall out, but not enough to worry about.


.

[joeyplumley]

thanks guys. I'll pull the cover tomorrow (don't know what would make it bind like that though, but I'll take a look....)

No kinks in the cable, and I made sure the lever and cable were all in sync first thing. I know the cable was free because I bought it with the damaged linkage - pulling the lever was super easy then since it wasn't doing anything!

I also know the linkage didn't break because of tough clutch engagement. The previous owner used some type of plumbing nut to fasten the drive sprocket on. This was too tall and chewed the linkage to shreds. I'm betting that's when he said "the heck with it" and parked it. Which, was a good thing - I bought it for $100 - windshield, saddlebags and all.....