Clutch is quite stiff to operate.

[alehsv]

Good afternoon, everyone. Does anyone have experience with this combination of clutch parts? I’ve replaced everything—including the pushrod and the double ball bearing—and I also replaced, lubricated, and correctly routed the cable, yet the clutch feels quite stiff. The problem is that I don’t have a reference point for how it used to feel; I bought the bike a long time ago and have been repairing it bit by bit, so I didn't really notice the clutch stiffness back then. I suspect the springs might be the issue, which is why I’m looking for someone who has used them. Compared to my other bikes—a 2014 150cc Honda and a 1998 Honda Shadow—those are much smoother to operate.

Thanks.

 

[Wagner73]

Good afternoon, everyone. Does anyone have experience with this combination of clutch parts? I’ve replaced everything—including the pushrod and the double ball bearing—and I also replaced, lubricated, and correctly routed the cable, yet the clutch feels quite stiff. The problem is that I don’t have a reference point for how it used to feel; I bought the bike a long time ago and have been repairing it bit by bit, so I didn't really notice the clutch stiffness back then. I suspect the springs might be the issue, which is why I’m looking for someone who has used them. Compared to my other bikes—a 2014 150cc Honda and a 1998 Honda Shadow—those are much smoother to operate.

Thanks.



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I have the Mike's bolt kit installed, but Vesrah springs and well-cleaned & lubed stock mechanism. Clutch cable well-routed as well, and clutch operation is nice.

Many springs may be too stiff and/or too long. I would measure their uninstalled height vs your originals (I bought some springs for another bike but didn't install them bc their free length was too great)

There are also a number of threads on here about cable routing, depending on bar type, etc. A search should turn some up. Also, be sure to lubricate the cable well, even when new.

 

[alehsv]

I have the Mike's bolt kit installed, but Vesrah springs and well-cleaned & lubed stock mechanism. Clutch cable well-routed as well, and clutch operation is nice.

Many springs may be too stiff and/or too long. I would measure their uninstalled height vs your originals (I bought some springs for another bike but didn't install them bc their free length was too great)

There are also a number of threads on here about cable routing, depending on bar type, etc. A search should turn some up. Also, be sure to lubricate the cable well, even when new.

Hi, I've seen all the threads about this, but I still haven't found the error in mine—or maybe that's just how stiff it is. I'm going to try putting back the original parts to see if it improves.

 

[Wagner73]

Be happy to help if we can. I guess I'm used to the cable clutch actuation of this vintage of bikes, so I may not be the best gauge. I will say that I would be surprised if this clutch actuation was as easy as a 2014 150cc Honda and a 1998 Honda Shadow, the former for obvious reasons, and the latter bc it's a 20+ year newer design.

 

[gggGary]

Did you remove and check the clutch lever pivot bolt, they are often dry and horribly worn out.
Are you using the long or short pivot hole on the clutch harm?
Is the cable a new motion pro cable or some ancient (rusty) old cable.

 

[alehsv]

Did you remove and check the clutch lever pivot bolt, they are often dry and horribly worn out.
Are you using the long or short pivot hole on the clutch harm?
Is the cable a new motion pro cable or some ancient (rusty) old cable.

I have a new lever, a new lubricated and routed cable, and a new, greased actuator assembly; I’m also using the mounting hole furthest from the pivot. That’s why I think either the springs are too stiff, or that’s just how heavy the clutch pull is on these bikes. Like I said, I don’t have a direct "before and after" comparison—I only have other bikes with different clutch systems.

 

[gggGary]

What year is the engine (clutch pac)?

 

[alehsv]

What year is the engine (clutch pac)?

1979

 

[gggGary]

Well yeah compared to most modern bikes pull is kinda heavy, but I've had bikes with heavier clutch action.
Check your spring length?
https://www.xs650.com/threads/clutch-spring-length-confusion-some-bits-sorted.63843/
too long springs might be binding at full lever.

 

[Jim]

Not having the dots on the outer basket and pressure plate lined up can cause a stiff clutch also.

 

[Kevin Werner]

I have a new lever, a new lubricated and routed cable, and a new, greased actuator assembly; I’m also using the mounting hole furthest from the pivot. That’s why I think either the springs are too stiff, or that’s just how heavy the clutch pull is on these bikes. Like I said, I don’t have a direct "before and after" comparison—I only have other bikes with different clutch systems.

Take your tank off!!! Now install the cable unrouted, just free, on the left side of the frame and then on the right side to see which pulls better. Now start tucking the cable in to where it would be with the tank on. With many tries you should find a good cable placement. Cheers.

 

[alehsv]

Thanks everyone for your suggestions; once I check the springs, I'll let you know how it turns out.

 

[alehsv]

An update: I took apart the clutch and replaced the springs with the original ones; there’s been an improvement, and I can now engage the clutch more easily. Thanks, everyone!