Not enough spring tension on clutch cable

Another first for me...

I installed a new clutch cable tonight. This is an aftermarket cable from Chacal and it's a coupled of inches longer than the OEM version. Bike is not running yet, so this has nothing to do with the operation of the clutch itself - just cable operation.

I have the sleeve/housing tightened up on both ends, but there does not seem to be enough spring tension to draw the lever back after it's been depressed. I followed bigFitz's instructions from another thread regarding how to make sure the throw-out arm is in the proper position.

When I twist the throw-out arm by hand with the cable detached, it feels like there is decent spring tension. However, with the cable attached, it won't even draw the lever back into position.

I have two questions. The first a is a VERY basic new cycle owner question: Does a brand new cable need to be lubed before it's installed? The cable felt so silky smooth moving through the housing before I installed it that I assumed not.

Second question has to do with cable routing, turns, bend, and friction: With the extra length of the aftermarket cable, it has to be routed in such a way that there is a bit of extra bend in it. None of the bends are what I would call sharp, but there's certainly a little more rubbing going on in there than there would be with a shorter cable.

The basic principles of clutch cable adjustment don't seem to me like rocket science. The housing has to be secured on both ends and the throw out arm has to be positioned correctly. I did read and print out Rick's tutorial on the subject. Maybe I'm missing something else...

Thanks...again!

 

YES!!! Although, they need to be lubricated before they are first used, rather than merely "installed".

 

OK, I bought some cable lube that came with a lubing clamp which seemed to work well. Unfortunately, it made no difference in the way the lever operated. However, I have isolated at least most of the source of my problem to two things.

First, I had stripped and straightened the clutch lever, then recoated it with Plasti-Dip spray. Although the lever was still quite loose in the mounting bracket, I think the coating may have created a small additional amount of drag. I scraped away any coating from where the lever slides into the bracket and applied a little silicone grease.

Second, the angle at which the cable enters the knurl up by the lever seems to be a critical factor creating extra friction. My knurl is fairly worn and the end of the cable housing just doesn't fit in there very tightly. Even with the cable routed very deliberately, it still wants to sag just a bit so that the cable itself rubs a little against the metal bullet(?) on the end of the cable housing. Boy, a little friction sure makes a big difference on this.

I've taken a couple of layers of plastic cut from a milk jug and wrapped them around the end of the cable housing like a little spacer or bushing. Then I wedged it into the knurl so that it would essentially square up the angle that the housing meets the knurl. That seems to be working OK. There isn't a lot of tension there, but at least the lever will draw back now after it's squeezed.

 

The little return spring on the throwout lever doesn't exactly "snap" the lever back; it more or less just keeps everything from flopping around.

 

That's good to know. Doesn't sound like mine is too far out of whack, then.

Also, how much up and down play should there be in the lever? Mine feels like the bracket has spread or perhaps like I might even be missing a spacer or washer meant to hold it steady.

Thanks!

 

im having the same issue with my 750 maxim. replaced it,a dn it feels like there is no pull at all.