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As previous incomplete query. In assebling a basket case B40 it appears that the inner cable of the clutch cable is approx 65mm to long..I acquired a new cable which was exactlt thje same length. The inner rod is correct & the ball fitted to the cup... If I take the lever to the maximum extremity to allow the cover to be fitted the cable would still be to long even with the handle bar lever adjuster at maximum...It is strange and I must be missing something simple that I cannot see at this time.. I did'nt think I was stupid but now I am wondering ..Help ???

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  • 157 Answers

I am not familiar with your model. However what I can think of that would cause the symptom you have with a basket case assembly: Improper clutch assembly( pressure plate not engaged properly with inner clutch hub; needs to be rotated 1 or more teeth so as to seat fully on plates), improper plate stacking or # of plates. Incorrect location of clutch cable mounting bracket. If clutch arm is of the splined type, incorrect placement on the splined release shaft. hope something helps

Posted on Dec 30, 2012

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6ya6ya
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Posted on Jan 02, 2017

  • 2712 Answers

SOURCE: Clutch cable adjusters

Bowden cables like your clutch cable work on the law of the lever. Think of lifting up a heavy weight hanging on a rope using a lever balanced on a fulcrum. The rope is in tension and the fulcrum is in compression. To adjust the point of lift you could either vary the length of the rope or adjust the height of the fulcrum. The outer sleeve of your clutch cable is made out of plastic-coated steel, square-section wire and is resistant to compression forces along its length. This outer sleeve works as your fulcrum and, because it is flexible, lets you put it where it is needed - at the end of your handlebar. The cable inner is like the rope in the lever example and resists only stretching forces. It is threaded down through that snaking fulcrum back to where control movement is needed. The cable adjusters let you fine tune the length of the fulcrum, and therefore the lift range of the inner cable.,,,

Posted on Nov 10, 2008

  • 1 Answer

SOURCE: V-star 650 yahama 2009 to much clutch play

There is a clutch linkage kit you can purchase which will take the "**** " out. It is mounts between the end of the clutch cable and the transmission. I have one on my bike and love it. Easy to adjust and customizes the clutch to you.

Charles

Posted on Jan 31, 2009

  • 25 Answers

SOURCE: replaceing drive belt 2001 road king

you will have to remove the compesator nut and the circlip in the centre of the clutch hub , remove the nut securing the clutch basket on (left hand threads on this nut so be carefull ) remove the little jackshaft nut and stater gear then remove the 2 bolts holding the starter motor on then you will find 6 or so bolts holding the inner primary case on remove these and the inner primary case will come free with a little jiggle. unfortuantaly you will also have to remove the rear wheel ,suspension and swing arm to get the new belt on. hope this helps
regards
bert31000

Posted on Mar 18, 2009

ginocussen
  • 216 Answers

SOURCE: i just got a new clutch cable for my 1980 yamaha

check there are no kinks or sharp curves in the cable, that it routes cleanly. Otherwise you need to look further at the clutch itself.

Posted on May 04, 2009

  • 17 Answers

SOURCE: 74 honda TL125 with a free play feel in the clutch leaver

On most bikes, there is a rod going down the center of the clutch. The lever on the case pushes this rod in when you squeeze the lever on the handlebar. If the rod going through the clutch will not move, the clutch will not release. It doesn't move very much, maybe a few millimeters. If you cannot remove the rod[you may have to use a magnet to pull it out] then the rod is bent. This could have happened if you assembled the new clutch incorrectly. If the sequence during reassembly was wrong, the disks were jammed. When you squeezed the clutch lever, something had to give. The clutch rod.

Posted on Sep 21, 2009

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I have a 1994 yz125, when I pull the clutch leaver in it won't spring back.I thought it might be the clutch cable so I got a new one but it still does the same thing. how do I fix this?


Keenan:

I'm not too familiar with the YZ125. If the clutch lever (where the lower end of the clutch cable connects) is on the outside of the transmission case, see if you can push the lever back and forth. Feel for resistance If the clutch lever moves both ways freely, the clutch return spring in the clutch is broken, or the clutch has failed. You'll have to drain the engine oil and remove the clutch cover. Then remove and disassemble the clutch to replace the return spring... or take it to a shop and have them do it.

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Hello,
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you will have to remove the compesator nut and the circlip in the centre of the clutch hub , remove the nut securing the clutch basket on (left hand threads on this nut so be carefull ) remove the little jackshaft nut and stater gear then remove the 2 bolts holding the starter motor on then you will find 6 or so bolts holding the inner primary case on remove these and the inner primary case will come free with a little jiggle. unfortuantaly you will also have to remove the rear wheel ,suspension and swing arm to get the new belt on. hope this helps
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