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TECHNICAL MOTOBRICK WRENCHING In Remembrance of Inge K. => The Motobrick Workshop => Topic started by: plumberdude on May 23, 2012, 11:56:07 PM

Title: clutch problem, need help
Post by: plumberdude on May 23, 2012, 11:56:07 PM

The clutch cable broke and I had a spare which I was able to partially install. The reason I haven't finished is that I don't have enough slack to screw in the male part at the handlebar. It seem like there is hardly any movement in the part that pivots at the trany end. It moves maybe a 1/4". I tried to pull up on the pivot part to see if the clutch would disengage but it won't. Any ideas?

Title: Re: clutch problem, need help
Post by: Rick G on May 24, 2012, 02:03:10 AM

Do the bit on the handlebar first then lever up the lever on the transmisssion and pop the cable end into the slot.
If the lever wont move easily then it needs to be taken out and the bearing repaired. Down there in front of th rear wheel they have a very hard life and the rust quickly sets in once the grease has gone.
That lever has a fair tension but you should be able to move it and disengage the clutch by hand, a small lever makes it easy.

Title: Re: clutch problem, need help
Post by: Scott_ on May 24, 2012, 07:03:23 AM

Also check for any type of road debris down around the lever that may be getting wedged between the lever and the trans housing.
It's not easy to move the lever by hand. You will need something to give yourself a little leverage.
When you are putting the cable in at the handle end be sure to lube the barrel in the handle but be very careful to not get any lube on the cable itself.

Title: Re: clutch problem, need help
Post by: plumberdude on May 24, 2012, 12:04:20 PM

Thanks, I got it, putting in the handle bar part first did the trick. Before I started I looked for any info on how to install the cable and couldn't find any until last night I checked my Clymer manual again and found something. They said to take the gas tank off which I didn't do, I attached a piece of 3/8 pex pipe to the cable when I was pulling it out and attached it to the new cable to pull it back through under the tank. I'm surprised by how much tension there is to disengage the clutch, I thought I could pull up on the pivot arm without too much force, I thought there was something wrong and didn't want to force it. Anyway all is good. Thanks for your replies.