clutch problem

[Pol Anorl]

Thread #2

riding along it got really hard to change gear, then id realised the clutch lever had gone really light and clutch touched the bars with no problems.

adjusted cable on the bars and its now fine...

What happened?

last oil chance was 250-300 miles ago, new correct oil used and no clutch slip.

bike: fzs 600
cable to shaft for clutch

[mudcow007]

cable adjuster err adjusted/ slipped?

[Pol Anorl]

[Rogerborg]

<We're-All-Doomed>Cable is separating and will snap soon.</We're-All-Doomed>
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[Pol Anorl]

[Taught2BCauti...]

Just to make sure it's not something internal, what is the angle between the cable and the clutch release lever?

It should be less than 90°, like this:
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[316lad]

[Skudd]

ounds like not set correctly in the first place, but I would have a spare cable ready just in case. Easy enough to change, just getting it to how you like it is the bugger.
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[Taught2BCauti...]

I always think that the adjuster at the lever-end is the weakest part of the system, so I prefer to screw mine all the way in so there are no threads showing, and make adjustments at the clutch end.

Your problem might have been caused by the ferrule on the end of the outer cable not seating properly in the adjuster, then suddenly snapping into place, causing the slack to appear.

Someone on here recently had a clutch push-rod snap in half - but that would show-up in the angle between the release lever and the cable, as per my pic - but like Skudd said, better to buy a spare cable and keep it handy - just in case.
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Honda Varadero XL125(V8)
www.TheFutureIsHere.eu

[316lad]

x2 for having a spare cable.

Sod's Law states that the old one - if it snaps - will wait until you're more than 5 miles from home on a wet cold miserable night.

[Pol Anorl]

bastard to change on the fazer it goes inside the sprocket cover to a shaft.

need to carry allen keys and a 10mm spanner with me now.

note mine but from google
inside sprocket cover:
https://images.yuku.com.s3.amazonaws.com/image//17a366976715d9a56d086acda6fdd3151310e527_r.jpg

[Andy_Pagin]

I'd take the sprocket cover off and take a look at the clutch cam lever, it's held onto the cover by a couple of little screws, they might have come loose for example.

It's easy enough to do, slack off the adjuster at the handlebar, unbolt the sprocket cover. To refit scrape off any gasket bits, squidg a line of instant gasket in its' place and re-fit. IIRC the bolts aren't all the same length (or was that the Vity?, can't remember).
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[chris-red]

Cable is about to snap. Mine always break at the lever end and my TDM probably uses the same lever set up so yours may be doing exactly the same. have a look don't leave it, it will snap soon.
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[Pol Anorl]

will go take a look now will report back with findings

clutch cable at both ends seems perfectly fine.

no rust in sight free moving with no problems...

ill just ride it out its only what £15 for a cable i have rac cover.