Clutch Cable "Pop" Problem - HELP

[Drayno]

Well, out riding last weekend and my frigging clutch side mirror broke off again (3rd time); this of course caused the lever bushing to fall out after the mirror/bolt fell out on the road.

So... got a new bushing in the mail today and went to put everything back together, seems to go together fine and lever was solid again inside control housing. I went to adjust the clutch cable via in-line adjustment and it tightened right up about half way down threads (close to where it was before I loosened it). I squeezed the level a few times and heard/felt a pop: then lever went loose.

I figured I broke the cable, but I tightened the adjustment a little more just because and the lever/cable went tight again; however the clutch does not engage. I did not start bike but when I get it first, lever all the way down it does not roll.

I have not messed with many clutches, any as a matter of fact, but I assume if the cable broke the lever would be limp regardless of how must slack adjusted out.

I have read a few of the how-to's on adjusting the cable and have the exhaust off at this point. I am just wondering if anyone may have any ideas of what happened and which direction to head before I start royally fucking my shit up?

Thanks in advance,
Drayno

 

[FrankBDPS]

What bike do you have? sounds like you're cable end may have come out of the bell crank ( I think that is what it is called) on the transmission end. Good luck with getting it fixed.

 

[Th3InfamousI]

Ball and ramp not bell crank

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[Drayno]

That would help, 07 K-9.

So basically pull the clutch apart like Gas - man shows in how to and try to loop cable back in ball and ramp assembly?

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[boomer4444]

sounds like your ball and ramp has jumped, take it apart and regrease and reassemble correctly,, it sits on the right side of tranny where you adjust the clutch pushrod,,basic stuff

 

[woodbutcher]

if all you see is a raw end of a cable, only thing you can do is either send it back to Barnett and have them put a new end on it or order a new cable. there is really no self fix .

 

[FrankBDPS]

Ball and ramp not bell crank

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Hey it was 4:30 am. You don't need to pull the clutch apart. Just the cover where the cable runs into. Put a drain pan under it. There will be fluid there and you will need to top off the transmission. Good luck.

 

[Th3InfamousI]

Was early what about the clutch cable pin (horseshoe shape) that goes in the lever to hold the cable in place is that still there? Or is it jumping over that holding pin?

I hadn't put mine in correctly and it jumped in and out. Easy fix tho



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[woodbutcher]

Hey it was 4:30 am. You don't need to pull the clutch apart. Just the cover where the cable runs into. Put a drain pan under it. There will be fluid there and you will need to top off the transmission. Good luck.

if it is the ball and ramp, all you need to remove is the cover behind the exhaust where the cable goes in on the right side of the bike???? screws off rt/ll. will be tight so you might need a strap wrench. i seat a rubber mallet handle in one of the thumb slots and tap the head of the mallet with another hammer. helps to break loose the o-ring.

 

[boomer4444]

Hey it was 4:30 am. You don't need to pull the clutch apart. Just the cover where the cable runs into. Put a drain pan under it. There will be fluid there and you will need to top off the transmission. Good luck.

say what???? there should not be any fluid in the ball and ramp assembly!1 grease yes,

 

[boomer4444]

I figured I broke the cable, but I tightened the adjustment a little more just because and the lever/cable went tight again; however the clutch does not engage. I did not start bike but when I get it first, lever all the way down it does not roll

if the cable was indeed broke he would run out of adjustment threads on adjuster nut before cable got tight again, my thought is either ball and ramped jumped on the ball bearing or feral came unhooked at ball n ramp or clutch lever,, ball n ramp is good place to start

 

[FrankBDPS]

say what???? there should not be any fluid in the ball and ramp assembly!1 grease yes,

Sorry, my old beater is left side drive. Different animal.

 

[Olde Man]

It has been a while since this happened to me so I will try to get the memory thing going the right way. Mine popped and left me with a lot of slop in the cable. I think I must have allowed the ball or balls to come unseated from the ramp. If this happens and you adjust the clutch push rod with it like that it will have excess a lot of extra clearance when the balls seat themselves properly. As everyone else said maybe the clutch cable retainer wasn't properly seated and then popped into place. My guess is if that happened you would have been able to adjust it with the cable adjuster. I'm going for the broken cable end or balls not seated when the clutch push rod was adjusted.

 

[Drayno]

Just wanted to give a thank you to everyone who gave their input. Got the clutch apart and everything looked fine. Cleaning, Fresh grease and an adjustment she shifts smooth like butta.
Everything back together late last night and down the road. Pretty happy I got to learn a little more about my machine.

One more quick question, clutch engages about 1/3 of the way lever is being released. If I want clutch released closer to grip do I have to go back into bottom clutch adjustment? Does this mean I did not tighten push rod enough or too much?
Thanks again.

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[TapioK]

If you did the adjustment by the book with loose cable: turn in to touch, back ¼ turn, tighten the nut) I wouln't mess with it. If you loose it a bit it should move the action closer to bar, but will it disengage enough then? The neutral will be hard to find, bike lurches when shifting from neutral to first... Also do not adjust the cable too tight! There must be a little play on lever or clutch will slip. Like I said the movement on clutch is small.