Clutch: hard to pull?

When I set up my bikes,
I start with clean lubed parts, the cable adjusted to full slack, the jam nut on the worm screw adjuster broke loose and have the left side cover off.

I connect the cable to the worm screw arm and with the lever fully pulled, I adjust the cable at the perch until the cable is properly adjusted. The cable is properly adjusted when the cable and arm are at 90' degrees to each other, continue adjusting the cable 2mm past the 90'of the worm screw arm and cable.
( 90' IS VERY IMPORTANT IT IS THE MAXIMUM LEVERAGE POINT the 2 mm allows for cable slack and a full pull to 90' between the worm screw arm and cable.)

At this point I mount the side cover and torque the mounting bolts to spec.
Once the side cover is mounted adjust the worm screw until it makes light contact with the push rod and removes all lash to the pressure plate and back off the screw 1/4 turn and secure with lock nut.

Next I adjust the cable at the perch to remove all slack, after which I back off the adjustment to allow 2mm free play in the cable measured between the perch and lever.

I use MMM's Easy-pull cable that gives the proper length for the bike, when combined with the high ratio lever makes for a very easy lever pull.

Riksoto
 
Read through all the post...good info...had an 83 Special with a very hard pull. Put on a new cable(after dripping 10-30W oil through it), cleaned and greased the worm gear, when I tightened the worm gear housing down it squeezed the worm gear and rotated hard, I flipped the housing around and didn't tighten it down so hard and it rotated smoothly. My worm gear only had one hole (upper) so I drilled another one below it....put it all back together and it reduced my pull by 75+%%%%......I believe tightening down the worm gear housing too much was probably the primary problem...Thanks for the advice....:thumbsup:
 
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