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Message started by aearil on 04/25/18 at 11:10:23

Title: Clutch Lever Hard to Close
Post by aearil on 04/25/18 at 11:10:23

Hi all!

'15 Boulevard S40 with 13k miles on it. Only owner, I did all of the recommended maintenance through the dealer until late last year when I started doing it myself (with more or less success).

I've had an issue with the clutch lever being difficult to pull closed (disengage?). It's less like being stiff and more like a stepping motion - pull, stick halfway, release, pull all the way. At first it would only happen after I'd been riding at high speeds, but on my ride today it happened probably every third time I used the clutch (with some of these being described more as stiffness).

On a side note for consideration of damage caused by riding style - I ride almost every day and spend a lot of time on the highway and a good portion of that in traffic/splitting lanes.

I know very little of how a clutch works. I've done some research and here are my thoughts on it:

A) I probably need to use a better motor oil. Currently using Lucasoil 10W-40, but from what I read on this forum that's probably not great. I also usually replace every 3k miles since I'm mostly on the highway, and I'm at 2.6k now. Going to replace with Rotella T-6 5W40.

B) Damaged clutch cable. Could possibly be frayed and catching on something. I plan to take it out and check sometime today or tomorrow, once I do some research on how to do it!

C) I've read I might need a new clutch basket but I really DON'T want to do that.

Tbh I just want to know what's causing it so I can go about fixing it, but right now I feel like I'm shooting in the dark.

Some background for when you respond/ask questions:
I've only ever worked on this bike and some minor stuff on my Mini. I've been riding this bike three years, only started doing my own maintenance since late last year. That has mostly involved changing the oil, tightening some of the bolts and such to spec, replacing the front brakes, and installing heated grips. I know I'm due for a valve adjustment but I need to figure out how to do it first.

Thanks in advance!

Title: Re: Clutch Lever Hard to Close
Post by Serowbot on 04/25/18 at 11:24:02

Start with the easy stuff first..
Lube the cable, and make sure it has free motion.
Try some Rotella.

Cross fingers... :-?

Title: Re: Clutch Lever Hard to Close
Post by justin_o_guy2 on 04/25/18 at 11:44:23

The feel of mine changed
Not long before it
Broke.
Inspect it.
Look up underneath the lever.
Cable passes through a short rod, which is Supposed to rotate in the lever as the angle changes.
If it's not swiveling
The cable is being flexed in a short radius, causing the little wires to fray.

Title: Re: Clutch Lever Hard to Close
Post by aearil on 04/25/18 at 12:29:45

6E786F726A7F72691D0 wrote:

Lube the cable, and make sure it has free motion.
Try some Rotella.

Thanks, I'll try that! Would a regular lithium grease work for this or does it require a specific type of lube?

Title: Re: Clutch Lever Hard to Close
Post by Papa Bear on 04/25/18 at 13:44:22

I lube my cable with engine oil and grease the cable end with a copious amount of wheel bearing grease at the barrel end in the lever (the knarp)

Title: Re: Clutch Lever Hard to Close
Post by eau de sauvage on 04/25/18 at 19:38:22

I did all of the recommended maintenance through the dealer

There's your problem right there. Dealerships will not lube clutch cables because they couldn't really give a toss. Also doing it yourself will get you used to examining the bike closely which is essential to catch that rusty screw or loose bolt or some other thing that looks different to what you recall.

Agree with earlier comment that this might be a precursor to snapping. If, after it is oiled you find the problem goes away, it would probably be advisable to purchase a spare clutch cable and keep it on the bike. (ask me how I know)

As for what product you use, I'd venture to say just about anything is good. Make sure plenty goes in so that it comes out copiously at the other end.

If you're going to attempt the valves, it is not difficult but is very time consuming the first time you do it, it is an absolute must to use the motion pro feeler gauge to make life very very much easier. https://www.motionpro.com/product/08-0393 get two.

Title: Re: Clutch Lever Hard to Close
Post by justin_o_guy2 on 04/25/18 at 19:50:47

66797F7865625363536B79753E0C0 wrote:

I know what can happen and why it happens.
At least look up under it and squeeze the lever and see if it's swiveling enough to not be twisting the cable back and forth. Lubing the cable in its housing won't fix this.

Title: Re: Clutch Lever Hard to Close
Post by Dave on 04/26/18 at 04:16:43

Cables and levers need to be maintained, as the lube tends to collect grit.

Remove the lever and cable, clean the pivot points including the cable end. The cable can be lubed with a "cable luber".....or Oldfeller pokes a hole in a baggie and pushes the cable into the hole - then tapes the baggie to the cable, then puts light oil in the baggie and lets it seep into the cable for a day or two.

You need the cable tool and a can of spray.
https://www.amazon.com/Motion-Pro-08-0182-Cable-Luber/dp/B0012TYX9W

Title: Re: Clutch Lever Hard to Close
Post by justin_o_guy2 on 04/26/18 at 06:54:29

And if the rod isn't swiveling enough to not bend it, it's Gonna Break.

Title: Re: Clutch Lever Hard to Close
Post by Serowbot on 04/26/18 at 08:15:37

I generally use a thin spray lube that will mostly wash out the end eventually. I don't want oil that's thick enough to gunk up inside the cable and collect dust and grit.
Barely any oil remaining is the goal.

Title: Re: Clutch Lever Hard to Close
Post by MMRanch on 04/26/18 at 08:35:56

aearil

My Cristol Ball see's a new clutch cable in you near future ! ;D They don't cost that much anyway , put the new one on and if that don't solve the problem its no really big lost.

..................................................................

FYI , I use T-6 and change ever 10,000 miles or once a year (which-ever comes first) wether it needs it or not . My guzzi owners/maintance schule calls for T-6 type oil and change every 10,000 km. (6,200 miles).

Title: Re: Clutch Lever Hard to Close
Post by aearil on 04/28/18 at 13:18:30

Figured it out!

So I started by disconnecting the top of the clutch cable so I could A) inspect it and B) lube it. Lubed it, connected it back up. Adjusted the play, and when I went to test it... It got caught again!

Turns out the glue on my handgrip had broken loose. The hand grip would occasionally twist enough that the wire coming out of it (heated hand grips) would block the clutch lever from closing. I feel like an idiot but at least it works now. ::)

Title: Re: Clutch Lever Hard to Close
Post by Papa Bear on 04/28/18 at 13:53:10

I'm in Canada (the other CA), I wear gloves. ;)

Title: Re: Clutch Lever Hard to Close
Post by norm92de on 04/28/18 at 16:38:55

I have never had a clutch cable failure. All I have ever done is to turn the bars to the right to raise the clutch lever as high as possible. Then dribble a little engine oil, or whatever, on to the cable, pull the clutch a few times and a little more oil. That's it. The same with the front brake cable when we has them.

Title: Re: Clutch Lever Hard to Close
Post by batman on 04/28/18 at 18:24:39

Aearil have the heated grips been turned on long enough to kill your battery yet? How many watts do they draw?

Title: Re: Clutch Lever Hard to Close
Post by aearil on 09/18/18 at 18:43:01

7576637A7679232F170 wrote:

Aearil have the heated grips been turned on long enough to kill your battery yet? How many watts do they draw?

They haven't! I actually installed a new battery at the same time - the Duracell Ultra, I think? Haven't had any issues and it's been about 6k miles with them. They were a gift, so I'm not certain on specs but they look like these: https://www.amazon.com/Koso-AM10711F-Multi-Adjustment-Heated-Grips/dp/B00DTBU3YU/ref=sr_1_5?ie=UTF8&qid=1537321231&sr=8-5&keywords=koso+heated+grips.

I know they have an auto-shutoff when the voltage drops below 13V, but I haven't been brave enough to test that yet. :)

Quote:

I'm in Canada (the other CA), I wear gloves.

Well I find 45 F here to be my limit even with gloves, so.... ;D

Title: Re: Clutch Lever Hard to Close
Post by Tocsik on 09/21/18 at 12:08:24

5453565A585A060C3F0 wrote:

Had the same thing occasionally happen with my left side Oxford heated grip on my scooter, but it interfered with the rear brake lever. Finally took it off and sprayed old-fashioned hair spray on the bar, reinstalled, problem solved.