Clutch issue

[puzzle]

My GPZ500S has a very stiff clutch, the bikes done 9000 genuine miles and I can only guess the clutch is original. After about 20 miles (less if riding around town) the clutch lever is hard to pull in but comes back smoothly, it requires so much effort to pull in that the tendons in my hand/wrist ache! I have replaced the clutch cable with a new one, oiled it with motor oil prior to fitting but still the same problem and am using Halfords Semi-Sythetic motorcycle oil. I have tried going up hills in the higher gears (5th and 6th), the bike pulls ok without any sign of the clutch slipping.
Could the clutch be u/s even though it's not slipping and does anyone have any ideas on how to fix this pls? Thanks in anticipation.

[Ichy]

Check and clean the clutch pushrod and linkage for starters.
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https://www.metacafe.com/watch/1972097/how_to_behave_on_a_forum/

[puzzle]

Yes should have mentioned I have already checked pushrod and linkage - all clean and good.

[stinkwheel]

Is the cable routed correctly?

Try taking it round the outside of the tank as a test to eliminate this.

Some cables aren't supposed to be oiled, they have a liner in the cable outer which can be attacked by the oil.
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“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[puzzle]

Thanks for the help on this. I have routed the cable all ways, initially making a note of the original route. However, I have tried all different ways as there is enough slack but still same issue. Cable is ok for first 20 miles and then clutch just becomes harder and harder to pull in untill tendons are very sore. It's almost unrideable like this!!

[stinkwheel]

So it's the cable then?

Sure sounds like it. Have you tried undoing the bottom end of it to see how stiff the cable itself is? If it is stiff as hell, buy a new one but don't oil it. I usually just put a thin smear of grease over the exposed part at each end of the inner to keep the rust off it.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[puzzle]

It's a brand new cable which was not stiff atall before fitting with good free movement.

[Nath]

But what's important is whether the cable moves freely now. You can't start investigating further until you have disconnected the cable proved it still moves freely.

If the clutch only gets heavy after 20miles of riding, then you need to disconnect the cable after 20miles of riding and check it then. The cable does sound like the most probable cause to be honest (regardless of how new it is).
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Hard livin', hard luck.

[stinkwheel]