Stiff clutch

[Gzus308]

Hey all,

Been having some electrical issues and found a thread that said to check the stator wires so I took the left panels off to inspect and thought while I was at it I would clean the sprocket cover. So I took the clutch cable off and then took off the clutch rod corkscrew (don't know exactly what it's called) and cleaned and relubed the corkscrew then replaced it in what I thought was the original position. Upon reinstalling the sprocket cover and starting the bike up for a ride, I realized the clutch lever is now impossible to squeeze. I didn't Change anything with the cable other then taking it off then back on. Using a thread I picture I found here I setup the corkscrew exactly how it looked in the picture and it's still impossible to squeeze.

Thoughts?

 

[Nate7504]

I had a similar issue when I first pulled that assembly all apart, all I did was pull it off again and I pulled in and out the clutch rod thinking somehow it was hung up or the actuator was not quite alingened with the rod, that fixed it for me, I have no clue what caused it but that did the trick!
P. S it was a little tricky to see in the cover while reinstalling it, so to ensure the pushrod was seated in the center of the arm (there is a ball bearing in the center that pushes the clutch rod in) I pulled the rod out about six inches so I could be positive it was seated in the hole on the arm, then pushed it all in at once, cover and rod.

 

[bcware]

It might be best if you remove the cover again and take a photo of the clutch mechanism hidden behind the cover so we can see exactly what you did.

 

[drewpy]

there's a couple of ways the worm can screw in, make sure its in the right way. check against the manual

 

[Gzus308]

Here's some pics of where I have it set now. I tried many positions and turned the worm screw inlet 180 degrees. I found one position that was halfway rideable but I started it up and was able to stop the rear wheel with my hands in any gear which I believe is due to the plates slipping.

Never knew taking the sprocket cover off to clean would cause such a mess

 

[xschris]

Your way too far out. It should start with it all the way in. Then turn a little to hook to the cable. Takes a bit of tries if you have never done before but you will see once you get it. The pic is of what it should look like.

 

[drewpy]

turn it counter clockwise till it clicks in the track again. keep trying, there's no other way to do it really.

takes me a few goes

 

[Gzus308]

So I finally found time to try to fix the clutch. I continued to try to find that sweet spot where the wurm screw wasn't too far out but couldn't find it. Everywhere that sat that close didn't leave the stem in an area good for the return spring and cable. I ended up backing the screw and lock nut for now and got it ridable... But I want to do it right and get it sitting close like your picture. Is it possible to get a picture from the clutch rod perspective? Or is there a way to change the inlet to align correctly?

 

[xschris]

Too many things in the way to get a pic like that. Maybe take it to a shop and they can show you how it goes I will post 4 pics how to install it. From start to seated. If that don't help it's shop time

 

[Philodoxo]

Finally a cover, that looks like mine... all messed up in grease and dirt.

 

[xschris]

After cleaning

 

[Philodoxo]

Respect !!!

 

[Ezetman]

I took my side left side cover out for the first time yesterday and it seemed like it was the first time it had even been removed ('77). The dirt and grease in it was just a solid crust all in and around there.
I still have a hard clutch so I am gonna go back and check the gap on the "worm screw".