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Old 10-11-2012, 08:17 PM   #54076
TRZ Charlie
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Location: Fayetteville, AR
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Quote:
Originally Posted by Vinduroman View Post
Charlie:

Is the clutch hard to pull at the handlebar lever? Or, is it very easy to pull it in?

V-man

It's got some resistance as it should. The manual says 2-3 mm of pull where the clutch actuator lever attaches to the cable and that checks out too.
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Old 10-11-2012, 08:23 PM   #54077
Vinduroman
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Okay. Was wondering if you have a tight curve/bend in the cable routing under the tank or somewhere that was increasing the load on the cable.

Is the end of the cable pulling off... or the cable itself breaking? If breaking, is it breaking near the handlebar lever... or down at the actuating arm at the cases?

Were the ones breaking OEM cables?

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Old 10-11-2012, 08:27 PM   #54078
TRZ Charlie
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Quote:
Originally Posted by Vinduroman View Post
Okay. Was wondering if you have a tight curve/bend in the cable routing under the tank or somewhere that was increasing the load on the cable.

Is the end of the cable pulling off... or the cable itself breaking? If breaking, is it breaking near the handlebar lever... or down at the actuating arm at the cases?

Were the ones breaking OEM cables?

V-man
Breaking at the lever. The aftermarket lever was at a strange angle.

OEM cables and aftermarket cables.
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Old 10-11-2012, 08:35 PM   #54079
mouthfulloflake
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probably time to take that clutch cover off for a look then Charlie.

should be able to save the gasket if you are careful, or even better if mama zuki has gone to an O ring there.....
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Old 10-11-2012, 08:47 PM   #54080
TRZ Charlie
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I'm going to try to disengage it again tomorrow. When I tried to break it loose this evening I didn't have enough weight on the rear tire. I gotta think it is wet locked.
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Old 10-11-2012, 09:41 PM   #54081
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Good luck Charlie, I wish I knew enough about that to help.
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Old 10-11-2012, 09:44 PM   #54082
ozarkrider
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You've gotta adjust the clutch at the hub first. The adjustment at the cable is for just the cable. Gimme a call and I can walk ya through it.



Quote:
Originally Posted by DRZ Charlie View Post
I need clutch advice.

I replaced the aftermarket clutch perch and lever with an OEM clutch perch and lever because I keep breaking clutch cables. The clutch was working perfectly but it is at a slight angle which may contribute to stress on the cable.

When doing this I used the same cable that was on the aftermarket perch (and working) but after the replacement, the clutch actuator won't disengage the gearing.

I thought the clutch plates were wet locked so I lowered the bike and started it in neutral and pulled the clutch lever in and clicked it into gear and the bike died.

I did this three times and adjusted the lever from loose to tight and got the same result. Figuring that there was slightly better pull on the after market perch I put it back on and got the same result.

The manual states the the clutch actuator post should be rotated counter clockwise toward the engaged position (towards the center of the motor). It is positioned as indicated.

What am I missing here? The only other thing I can think of is the clutch actuator fork has somehow become fouled up. Thoughts?
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Old 10-11-2012, 09:45 PM   #54083
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Quote:
Originally Posted by DRZ Charlie View Post
I gotta think it is wet locked.
I've paid extra to be wet locked! just sayin.....
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Old 10-11-2012, 09:47 PM   #54084
ozarkrider
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Quote:
Originally Posted by joenuclear View Post
I've paid extra to be wet locked! just sayin.....
I can't say it, just can't say it.
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Old 10-11-2012, 09:50 PM   #54085
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Old 10-11-2012, 10:16 PM   #54086
TRZ Charlie
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I'm gonna put the bike back down on the ground and sit on it and try engaging it. If my weight isn't enough to break the discs from the wet lock I'm calling Joe.
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Old 10-11-2012, 10:22 PM   #54087
joenuclear
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Too late, I'm calling you.
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Old 10-12-2012, 03:35 AM   #54088
DrLewall
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mornin fellers

load that bike on the trailer and haul it out to the shop..we'll get your tire swapped out and Doctor on your clutch some (coy will be there too! )
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Old 10-12-2012, 05:39 AM   #54089
TRZ Charlie
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I can't get up Travis' drive with the trailer in the mud with my baby truck


Charlie
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Old 10-12-2012, 06:25 AM   #54090
Valentino Magoo
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Looks like we may get a little rain!
I am stuck home with a stomach bug. Sucks.

Chuck, I'd ring O'Jay. Seems unlikely you got something going on internally after just changing out the perch.
Occams Razor: simple explanations most often the correct ones.
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