Clutch bite point too high

[Pukka]

My clutch cable snapped the other day so ive had to replace it. (bike is a Honda CB500S)

However, before the cable snapped my clutches bite point would start around 40-50% of the lever travel from the handlebar. Now however the bite point is higher to around 70%-80% of the travel which is making it quite annoying to ride.

The cables got atm around 20mm freeplay (its max limit). Am i right in thinking that increasing the freeplay should move the biting point closer towards the bars?, because the lever feels very loose as it is at the moment and dont really want it any looser.

I've tried adjusting it with both the lever adjuster and the engine side adjuster and it doesnt seem to make much difference as the bite point is always too far away. The cable is routed the same way as the cable that i replaced.

Clutch itself was working fine before it snapped and upon letting the clutch out in 4th makes the bike stall so i think the clutch is still working as it should.

Thanks for any help

[Nick 50]

Just in case it helps:

https://www.scribd.com/doc/7180016/Honda-CB500S-9301-Service-Manual

Page 62.

Silly question, but is the length of new cable the same as the old one?

Sounds like the cable is a tad too long.
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[Pukka]

[dragstaar]

where are you adjusting the freeplay? try adjusting at the clutch end rather than the handlebar end.

[Pukka]

[dragstaar]

So there's no change at all when you are adjusting at the clutch end? The handlebar end is really for the small tweaks. You should see some change at least when adjusting at the clutch end. Seems odd that you're not

[Pukka]

Yeah the bite point is always around the later stages of the lever unless theres literally loads of freeplay (more than 30mmish and even then its still not close enough) which is then really uncofortable to ride with.

I think im going to take the tank/fairings off tomorrow to ensure its not catching on anything and the routing was actully correct in the first place and then try adjusting it again

[Pukka]

Well i took the tank of to get a better look and it definitly is being routed correctly as compared to someone elses.

I was also suggested to simulate lengthening the outer cable to see if it was too long by placing something between the lever adjuster and the outer cable to see if the cable was too long. However all that it did was mean less adjustment needed to be done but still resulted in the clutch releasing higher up the lever (again unless there was loads of freeplay).

I measured the point at which its starting to bite with this new cable which is around 5-6cm of travel from the bars with 8cm being the total travel of the lever. The point at which the clutch used to bite was around the 3cm area (and this is also the point on someone elses bike)

any suggestions?

[1cyl]

If the cable was too long, wouldn't the issue be "clutch not clearing properly?"

How about making the lever really slack when the clutch is engaged, to bring bite point closer to bar?

Personally: If there is a fraction of play in the lever when the clutch is engaged, with no slipping. And no snagging when breaking hard and going down through the gears while its pulled.........Id be satisfied it was adjusted correctly, regardless of bite point.
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[Pukka]