Clutch cable not retracting

[bankerbiker]

This is probably a simple problem for which I am just not seeing the solution. Unfortunately, as my wife will attest, patience has never been my strong suit.

I took the left side cover off the '83 XS650, and in doing so, I had to disconnect the clutch cable. The reason for the removal was to examine the alternator and area to see why I had an oil leak in this area. I also wanted to check on why the battery was not being recharged during a ride. I had taken the left side cover off the '81 XS650 that I recently picked up so that I could paint it. Painting was done and the cover went back on, including re-hooking the clutch cable with no problems. When I pull in the clutch on the '81 and release the clutch, it automatically returns to its normal position ready for the next clutch pull.

However, on the '83, when I now pull in the clutch and release it, it does not return to its normal position. It is as if the spirng has stopped working. But when I take the cable back off again and test the spring, it seems to work fine and has good spring to it. I tried several times to hook the cable back up and put the cover back on, all to no avail as the clutch lever does not return to its normal position.

Have I done something wrong in putting the clutch cable and cover back in place that it no longer works as it should? Is it possible the spring is just shot even though it seems to be fine?

Any suggestions would be most welcome. In the meantime, I have gone for a drink ... or three.

Thanks.

 

[Jim]

Remove the cable, clean and lube. They need fresh lube at least once a season. Odds are, that one's never seen an oil can.... ever. Even new ones come dry.
When you reinstall, big loops only, no tight bends. And a few loops as possible.

 

[bankerbiker]

Jim ... THANK YOU! With the help of some Youtube videos on creative ways to lube a cable without removing it from its track on the bike (and the help of my wife at one end of the cable) I was able to lube the cable and put everything back together again. It works! Based on the challenge we had doing this, Jim you are right - the cable had never been lubed. And then thinking about a bike sitting for ten years, while the engine may have been started, the bike was not ridden, or certainly not enough to keep those cables functional. I will do a test ride tomorrow, as long as the rain holds off.

Now I will have that drink.

Cheers!

 

[bankerbiker]

Did a test ride today before the rain started. Clutch worked fine and in fact the lever is now easier to work (less pull required so easier on the hand) than before giving it some oil.

However, came home to a gas leak so I replaced the pinch clip that had been over the gas line with a screw band that fits nice and tight. Hopefully that will work.

Pulled the left side cover off again to check on the oil leak from somewhere in that area. Seems oil is leaking from behind the alternator. Have discovered another thread from 2018 from Mailman that describes in detail how to change various seals in this area. Now to order the seals.

As my friend John reminded me, this is why I bought the bike - to learn all about this kind of stuff. I am getting my money's worth of learning!

 

[Jim]

- the cable had never been lubed. And then thinking about a bike sitting for ten years, while the engine may have been started, the bike was not ridden, or certainly not enough to keep those cables functional.

If the bike sat for all those years and never had lube on the cable, there's a distinct possibility it's rusting internally... which means it'll break at the most inopportune time.

Motion Pro cables are dirt cheap. Were it me, I'd change it and the throttle cable sooner rather than later. Might get you through this riding season, but definitely put it on the list of things to do this winter.

 

[bankerbiker]

Excellent suggestion Jim. With my time spent between this '83 and the "new" '81, I think this riding season will be ok. Good winter project.

 

[cra-z1]

Also make sure you have the routing correct.