Clutch

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Mart UK

Mart UK

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This is so basic it's embarrassing! Here goes...

Since I got the bike I've been struggling with how the clutch cable seats in the lever housing. To have any freeplay in the lever, it is adjusted to the point there is only about 1/4 of the adjuster sleeve engaged inside the handlebar housing. As a result the adjuster will move around inside the housing and it never sits flat against the housing. Clutch operation feels OK, smooth at 2 finger pressure.

I've replaced everything at the bar end, other than the clutch lever, which looks OK: the clutch cable, the adjuster sleeve and the handlebar switch and clutch lever housing. No difference. So, I'm thinking there must be something going on at the other end of the clutch cable, between the clutch operating lever / pushrod / clutch.

Anyone experienced and solved this?
 
All sounds normal. A picture of what you don't like would be helpful. The only things at the other end are: is the cable engaging in the arm properly, is the mechanism properly installed and aligned, and is the clutch rod adjusted properly. Remove the cover and watch as you pull the clutch to check the mechanism and cable. Check the clutch rod adjustment with the lever end completely loose.
 
Mine for comparison (with approx. 5/8" of the adjuster inside the housing from the 'low' point at the cable slot).
Clutch


How far are you backing off the pushrod as underadjustment of the pushrod results in overadjustment of the cable to compensate? Backing off the adjuster by "one full turn" as it says in the manual has been found to be too much.
 
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L.A.B. said:
Mine for comparison (with approx. 5/8" of the adjuster inside the housing from the 'low' point at the cable slot).
Click to expand...

L.A.B. said:
How far are you backing off the pushrod as underadjustment of the pushrod results in overadjustment of the cable to compensate? Backing off the adjuster by "one full turn" as it says in the manual has been found to be too much.
Click to expand...
Thanks for the photos. I am backing off one full turn on the clutch. Here's a couple of photos, struggled with focus. Nowhere near as far in as your adjuster.
 

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Mart UK said:
Thanks for the photos. I am backing off one full turn on the clutch. Here's a couple of photos, struggled with focus. Nowhere near as far in as your adjuster.
Click to expand...
Do you have the correct cable? Or is the nylon bush missing? Or just camera angle?
Half a turn from home on the clutch adjuster is plenty
 
Mart UK said:
I am backing off one full turn on the clutch.

Here's a couple of photos, struggled with focus. Nowhere near as far in as your adjuster.
Click to expand...

Something's not right there!
The inner cable has to be too long if it isn't due to the pushrod adjustment also assuming the cable entry at the gearbox is as it should be.
 
I'm getting my cables from Andover Norton, for the mk3. As was the replacement adjuster. This is my 2nd new one. Clutch adjustment feels fine on the road. No slip, straightforward to get neutral. I'll look again at that. I guess the operating lever in the gearbox has a gearing effect, but I can't see half a turn of clutch adjustmentmaking too much difference at the handlebar?

Did I see something about the mk3 having a different clutch lever to other models? Could the hole for the cable barrel be closer to the end of the switch housing, resulting in a shorter distance to the start of the cables sleeve? But that wouldn't explain why an AN cable doesn't seem to work. At the other end, the operating lever in the GB looks undamaged.
 
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Mart UK said:
Did I see something about the mk3 having a different clutch lever to other models?
Click to expand...
Introduced 73 or 74 a clutch perch where the pivot point is nearer the centre of the bike, its on my 74 but not my 72. Black is late, silver is earlier. So you could use a slightly shorter clutch cable but the extra length of the inner over the outer would stay the same.

Clutch
 
Mart UK said:
Did I see something about the mk3 having a different clutch lever to other models?
Click to expand...

There is a slight difference in the shape of the lever...
065878 Mk3.
Clutch


062072
Clutch


...the Mk3 pivot casting being different to the two in kommando's picture although the adjuster housing dimension is probably similar:
Clutch
 
L.A.B. said:
Mine for comparison (with approx. 5/8" of the adjuster inside the housing from the 'low' point at the cable slot).
Clutch


How far are you backing off the pushrod as underadjustment of the pushrod results in overadjustment of the cable to compensate? Backing off the adjuster by "one full turn" as it says in the manual has been found to be too much.
Click to expand...
Snap!! :) PS: Mick Hemmings preferred backing off one quarter of a turn on the diaphragm, 'not the half a turn it says in the manual' (Classic Bike: October 2009) Though Brian Slark (INOA) goes for the full one turn..

b
 
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EstuaryBoy said:
PS: Mick Hemmings preferred backing off one quarter of a turn on the diaphragm, 'not the half a turn it says in the manual' (Classic Bike: October 2009)
Click to expand...

Actually says one full turn in the pre-Mk3 and Mk3 manuals (but 1/4 turn in the early Commando manual).
Clutch
 
L.A.B. said:
Actually says one full turn in the pre-Mk3 and Mk3 manuals (but 1/4 turn in the early Commando manual).
Clutch
Click to expand...
Of this I am aware... though as MH also recommended Surflex plates in the same interview (which I omitted to mention) perhaps they suggest a smaller clearance??
 
EstuaryBoy said:
though as MH also recommended Surflex plates in the same interview (which I omitted to mention) perhaps they suggest a smaller clearance??
Click to expand...

Makes no difference between standard 5-plate bronze and Surflex as far as I can tell. One full turn does seem too much regardless of the plates used.
 
Your handlebar nipple looks to be undersize, when I have had cables supplied with small nipples they also came with a nylon sleeve so they fitted the lever snuggly.
 
Mind you... and I will get slaughtered for quoting these, but Haynes manuals give the: 'One turn' for Commando, but: '1/4-1/2 turn' for pre-Commando...
Though of course spring arrangements/lever profiles differ too?.....
 
kommando said:
Your handlebar nipple looks to be undersize, when I have had cables supplied with small nipples they also came with a nylon sleeve so they fitted the lever snuggly.
Click to expand...

Looks like it has the nylon sleeve as mine does in my picture with the nipple in a similar position.
Clutch
 
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Yes, it has the nylon sleeve and I don't think that would make the difference? It's probably 1/2" further out than LAB's photos. Puzzling.
 
Have you tried adjusting the clutch to less than half a turn yet?
 
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