Hitchcocks Forum

Hello forum users. My clutch gradually got heavier and heavier over winter until it was so stiff it felt like the cable was about to snap. I got our hosts soft clutch springs, new cable and changed the ATF but its still very hard. I have checked and re greased the rod inside the cover and re routed the cable through various different options. The only thing I haven't done is change the plates. The engine is a 99 500 iron bullet and has only done 8K from new. It's marginally better since fitting a new cable but I still need a left forearm like Popeye's and riding through town is hard work. Anyone got any advice on how to make it easier to operate?

Are there any adjustments you could make just inside where the cable goes in, to alter angles of levers etc? Don't know how else to say it! Good luck, Chris

I meant, at the gearbox end of the cable, not the handlebar end, of course.

Are you sure the cable is running free?
Greased the operating arm spindle?

Hi Chris, I had similar problems some time ago, if you hav'nt done so already take the cable out of the casket and let it hang free, for me it made a world of difference, I also removed all of the clutch plates and filed off any sharp edges from the splines, hope that helps..

CT -
You must be doing something wrong, or you've overlooked something.....
On my 2002 iron Bullet with standard lever, springs,etc. AND cable running through the nacelle, I can operate the clutch lever with one finger.
Did you oil the cable i.e. with the cable hanging vertically, run thin oil in at the top until it ran out the bottom, before fitting? Did you check for ease of movement, and lube the handlebar- and g/box levers ? Have you carried out all adjustments correctly?.... Don't bother changing the plates - this will make no difference whatsoever to the release effort required.... HTH

Hi guys---------I have a 2005 Classic 500 with MINDA levers, and a 1992 Classic 500 with MAGURA levers and neither of these types are "heavy" to operate or slip under load... On both of them the cables pass through the Casquette..You must be doing something not quite right , shall we say ?? or missed something, maybe ??.. Have you taken the complete push-rod out and checked for rust etc ??re-reading your first post it must be something within the system that you've NOT changed then, as the symptoms are still there...Also from that posting it would appear to be something to do with useage and wear as it was ok to start with ????

Thanks for the replies. To be honest I didn't oil the cable till it was running out the other end as I thought modern cables were nylon lined and didn't need it. Back to the garage tomorrow to try oiling!

Chris,
One thing might be worth a try, with the outer primary cover off back the three clutch centre studs out a couple of mm and see if this eases the pressure required. Try kicking it over and see if the clutch slips. I have at times fitted washers under the pressure plate onto these studs to allow the springs to be able to compress comfortably

Try Googling` Motorcycle Clutch Tuning` by Pete Snidal.
I`ll try to post it here.
http://www.snowvalley.20m.com/bikes/clutches.htm