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Clutch...

Discussion in 'XJ Technical Chat' started by Mixam, Sep 17, 2007.

  1. Mixam

    Mixam Member

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    Ok so yesterday my cable snapped at the handle. My dad and I were trying to devise our own redgreen style clutch handle (duct tape), and found that with the clutch "disengaged" it wasn't actually disengaging. My understanding is that the arm on the casing only moves a small amount. (You can move it with your hand). But for some reason, when pulling the cable to turn the arm, it wasn't pulling the clutch. How far is the arm supposed to swing? It only swings about a 1/4 of a turn for me. Other than that, it won't go any further.

    Thanks.
     
    Mixam, Sep 17, 2007
    #1
  2. Robert

    Robert Active Member

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    That is plenty. Throw length isn't terribly long for these bikes. I am not handy with the camera and I don't know how to elaborate the description forming in my head so I'm going to tell you to check out Rick's Clutch Adjustment Guide (hit the search function or contact him directly). That should help you on your way. Hope you get a new clutch handle soon.
     
    Robert, Sep 17, 2007
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  3. Danilo

    Danilo Member

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    It goes further than that :) You've just taken out the free play.
    Try this:
    grab the clutch arm with a pair of Visegrips (V carefully so you don't chew it up) then with the leverage the grips give you should be able to turn the arm against it's internal springs. If this doesn't do what you expect then there are other things wrong in the clutch mechanism..
    More than likely yr cable is shot.. a New clutch cable is in the $40 dollar range... but there is NO substitute for the OEM part... so lose the Red Green ambitions.
     
    Danilo, Sep 17, 2007
    #3
  4. Robert

    Robert Active Member

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    Thanks Danilo!
     
    Robert, Sep 17, 2007
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  5. dinoracer

    dinoracer Member

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    One of the main reasons for a clutch cable breaking is from lack of cleaning and lube. The more strain it takes to move the cable, the more tension is put on the cable itself. When you get a new cable, look into one of the lubing tools and some cable lube and keep the throttle choke and the clutch cable lubed up at least once a month.
    The worse part is that you usually do not realise that it takes more pressure to operate the clutch until it's too late, and you get that fatefull snap at the light. Then its waddle waddle, duck walk the bike up to operating speeds, Carefully put it into second gear and limp home.

    Sean
     
    dinoracer, Sep 17, 2007
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