Clutch Cable Falling out of Clutch Adjuster

[dkenn]

Example: when pulling in the clutch, the cable went slack completely, stalling the bike and rendering it inoperable with no tension in the lever. Then its stuck in gear and cannot be put in neutral. The end of the cable fell out of its slot in the push rod adjuster.

This is the second time this has happened in the last two weeks and it first happened a couple days after adjusting the free-play in the lever.

I thought I had fixed it the first time and was a weird anomaly. Going to stop riding until I figure out why its doing this as getting stranded is getting inconvenient. Any suggestions? I need to replace the cable anyway but I dont believe it’s the culprit of this problem. Im thinking the adjuster needs to be set correctly but not sure when/how it would have become incorrect. I had the cover pulled off last year but didnt have any problems with it.

 

[CaptChrome]

Did you adjust the clutch from the outside of the side cover first before adjusting the barrel adjuster at the lever? Since you didn't mention it, that could be your issue. Under the black plastic cap on the side cover is a 10 or 13mm locknut and a JIS screw that is used for the main clutch adjustment. The screw gets turned in until it bottoms out on the clutch push rod and then is backed out ¼ turn and locked down with the nut. After that, you make fine tuning with the barrel adjuster at the lever.

 

[dkenn]

I did try but the screw/locknut were pretty stuck. I realize now that its not necessarily the clutch cable disconnecting but I think that spring hook is falling out of its bottom hole seen in the picture I attached. Do you think the correct tension adjustment will stop it from loosening enough to fall out?

I got some WD40 on there so lets see if I can get that screw loose.

 

[CaptChrome]

Regarding the spring, you can always try and close up the end hooks a little with a needle nose pliers. Can't hurt.

The lock nut is a 12mm. The adjuster does need to work properly, so I would just put a 12mm deep socket in there and lay into it to loosen things up.

 

[dkenn]

Regarding the spring, you can always try and close up the end hooks a little with a needle nose pliers. Can't hurt.

The lock nut is a 12mm. The adjuster does need to work properly, so I would just put a 12mm deep socket in there and lay into it to loosen things up.

Thanks. Yeah it was stuck big time. I ended up taking the cover off, took the adjuster out, and placed the locknut in a bench vise and just knocked it free. I placed it back in and adjusted it 1/4 turn out like you said then closed up the spring a bit more. It's been about 8 days of riding daily and havent had a problem since. Hell it shifts even better now.

 

[kebabs]

Thanks. Yeah it was stuck big time. I ended up taking the cover off, took the adjuster out, and placed the locknut in a bench vise and just knocked it free. I placed it back in and adjusted it 1/4 turn out like you said then closed up the spring a bit more. It's been about 8 days of riding daily and havent had a problem since. Hell it shifts even better now.

Good you got it fixed

 

[kebabs]

Good you got it fixed

capt chrome will keep you right