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TECHNICAL MOTOBRICK WRENCHING In Remembrance of Inge K. => The Motobrick Workshop => Topic started by: dougrs on March 19, 2015, 07:38:09 PM

Title: fixed a stiff clutch lever
Post by: dougrs on March 19, 2015, 07:38:09 PM

My new to me '94 K75 had an extremely stiff clutch lever. I did a bunch of reading about the clutch cable and replaced it today. I included a picture of what the old cable looked like. It appears that a lot of lube had been applied to the cable. The new one feels so much better. Looking forward to taking the bike for a spin and not having to really muscle the clutch lever. And the clutch activated sidestand retraction works now too.

Title: Re: fixed a stiff clutch lever
Post by: Motorhobo on March 19, 2015, 08:58:49 PM

Clutch cable needs no lube except a touch of grease at the ball end at the lever where the cable meets the ball...friction can ensue there causing the cable to fray and snap. All of my snapped cables have been at that point.

Title: Re: fixed a stiff clutch lever
Post by: rbm on March 20, 2015, 07:27:21 AM

I've also read taht the feltring 32721231610 should be used to prevent cable fraying and snapping at the handle.  #9 in the diagram below.
(http://www.realoem.com/bmw/diagrams/o/a/6.png)

Title: Re: fixed a stiff clutch lever
Post by: Motorhobo on March 20, 2015, 09:11:21 AM

The felt piece was included in the last OEM cable i got last year -- about 70 bucks but the lever travels more easily on the black brick with the OEM cable than the red brick with a new aftermarket cable.

Title: Re: fixed a stiff clutch lever
Post by: dougrs on March 20, 2015, 11:00:24 AM

My new cable does not have the felt piece, but it still feels way better than the old abused cable.

Title: Re: fixed a stiff clutch lever
Post by: The Mighty Gryphon on March 20, 2015, 12:48:07 PM

If I am not mistaken, the felt is in the sleeve of the adjuster.  If it isn't there I would get it and put it in.  Keeps dirt out of the cable.

I don't know what other owners do, but I have a small oil can on a shelf next to where I keep my bike.  I put a drop of SAE 30 oil on the barrel at the end of the cable at least once a week. 

Title: Re: fixed a stiff clutch lever
Post by: johnny on March 20, 2015, 12:59:47 PM

my 94 11 hundert rs clutch cable broke at the top at 80k...

my 96 11 hundert rs clutch cable broke at the top at 100k...

both frayed cable inside the jacket a few inches from the top...

neither ever receivex lube other that some honda molly 60 at the nipple...

j o

Title: Re: fixed a stiff clutch lever
Post by: mrt6644 on October 18, 2025, 02:48:11 PM

I am a newish K75 owner.  Just got my 94 K75 on the road, and it rides great.  But catch lever has become super stiff and I am unable to pull it all the way in.
Im hoping its just the cable and not the actual clutch

Title: Re: fixed a stiff clutch lever
Post by: frankenduck on October 19, 2025, 11:05:13 AM

Is the side stand down?

Title: Re: fixed a stiff clutch lever
Post by: mrt6644 on October 19, 2025, 11:13:30 AM

Hmm. I think so.  Will check now.  Thanks

Title: Re: fixed a stiff clutch lever
Post by: frankenduck on October 19, 2025, 11:31:44 AM

The clutch lever retracts the side stand as a safety feature.

Title: Re: fixed a stiff clutch lever
Post by: mrt6644 on October 19, 2025, 11:34:55 AM

Yes, the side stand was down.  When its up its normal.  Thank you.
I looked and saw that lever that bumps into the side stand hardware.
Wondering if my side stand hardware is damaged.  The bike leans way past any sensible lean, even for a K75.
Also, the clutch lever has no effect on the side stand.  I try pulling and nothing.  Wondering if its all out of whack.

Title: Re: fixed a stiff clutch lever
Post by: Laitch on October 19, 2025, 12:25:07 PM

Quote from: mrt6644 on October 19, 2025, 11:34:55 AM

The bike leans way past any sensible lean, even for a K75.
.  Wondering if its all out of whack.

So you've seen a lot of leaning Bricks? Where do you live?  :laughing4-giggles:  Over here they as rare as dancing swans. Anyway, most new owners are appalled at the lean angle but try to push it over at that angle. Not happening. The side stand bushing or even the side stand itself could be worn but they're pretty tough. Put the Brick on the center stand, swing the side stand outward until it stops, grab the tip of it and see how much it wobbles on its bushing. Give us the grisly details in millimeters.

Watch the attached video and follow its instructions carefully—all of them. The clutch lever free play of a K75 is roughly 2mm. If the lever has no free play the clutch disc wears faster and shifting is no fun either. If you don't know what free play is, grab the bar grip, put one finger on the lever and gently pull the lever. The lever should easily move until the space between the lever and its mount is 2mm or so. If you feel immediate resistance, the clutch is out of adjust. Lube the clutch arm, lube the cable barrel at the clutch hand lever then perform a basic clutch adjustment in the sequence shown by the video. By the end of all this, you'll actually know what's what.

https://www.youtube.com/watch?v=gBW4D2jDw2A (https://www.youtube.com/watch?v=gBW4D2jDw2A)

Title: Re: fixed a stiff clutch lever
Post by: mrt6644 on October 22, 2025, 02:30:30 PM

I replaced the clutch cable.  Feels better but the one I replaced wasn't awful.  But good to have a new one in anyway.

The video is great.  I was wondering how to add freeplay and fix the side stand retractor function.

Title: Re: fixed a stiff clutch lever
Post by: Laitch on October 22, 2025, 04:01:40 PM

Quote from: mrt6644 on October 22, 2025, 02:30:30 PM

The video is great.  I was wondering how to add freeplay and fix the side stand retractor function.

Setting side stand retraction is in the video; setting free play is in the video. How can we clarify those instructions?