New engine, new clutch problem

headshrink · August 15th, 2011, 09:48 PM

I'm starting a new thread on my [new] clutch problems, because it is now on a new engine (1.2K miles).

I want to cry.

I am now having the SAME problem with the clutch on my new engine, that I had on the old one The friction point is all the way out, and the cable has a ton of slack... How on earth can the new clutch in the new engine have the same problem as my old clutch, in my old engine. The only part that is the same is the clutch cable. I see zero signs of damage or fraying. I don't think it could be too stretched, because if I don't loosen the heck out of it, the problem gets worse. If I adjust the cable the way it is supposed to be, my hand won't even open wide enough to release the clutch smoothly.

Since I got the engine from a 2010 salvage from an ebay wrecker, I don't really know the history of the engine, but it sure was clean, and had no visible signs of damage. I also have another thread open about a whine.... the current theory I am chasing down is possible an over-tight cam chain. With 1.2K miles, it SHOULDN'T have had the valve cover off, so it probably didn't have botched work for the cams or valves. I really don't even know what to think anymore.

I don't know what to do, but cry...

Skippii · August 15th, 2011, 10:23 PM

Is the clutch fully engaged with no slipping without a cable? If so, then the problem is the cable/lever/adjuster.

headshrink · August 15th, 2011, 10:31 PM

Quote:

Originally Posted by Skippii

Is the clutch fully engaged with no slipping without a cable? If so, then the problem is the cable/lever/adjuster.

Correct... I think. I just ordered a cable, although I see no damage on the old one. I've done so much chasing my tail this year, that I needed to know it wasn't the cable, so I'm glad you said that.

dubojr1 · August 16th, 2011, 05:25 AM

Keep us updated Bob.

cwb48 · August 16th, 2011, 07:32 AM

Quote:

Originally Posted by headshrink

I don't think it could be too stretched, because if I don't loosen the heck out of it, the problem gets worse. If I adjust the cable the way it is supposed to be, my hand won't even open wide enough to release the clutch smoothly.

When the clutch lever free play is adjusted correctly, the "friction point" is very close to the lever being all of the way out (engaged). You should only need to pull the lever in an inch or so (at the outside end) to disengage the clutch.

Could it be that you have unusually small hands? In that case, a set of adjustable levers could solve your problem.

Chris

Jinx250 · August 16th, 2011, 08:21 AM

Where in CA are you?

headshrink · August 16th, 2011, 10:37 AM

Quote:

Originally Posted by cwb48

When the clutch lever free play is adjusted correctly, the "friction point" is very close to the lever being all of the way out (engaged). You should only need to pull the lever in an inch or so (at the outside end) to disengage the clutch.

Could it be that you have unusually small hands? In that case, a set of adjustable levers could solve your problem.

Chris

Hands aren't too small... I didn't have a problem until the last couple months, and I have been riding for 3 years.

headshrink · August 16th, 2011, 10:38 AM

Quote:

Originally Posted by Jinx250

Where in CA are you?

Sacramento area

ninja250 · August 16th, 2011, 10:51 AM

Sounds weird, man.

You dive in the clutch yet to see what's poppin'?

Is it the oil you are using or something?

The clutch is way out at the end of the pull on this bike for me currently.. but I think it's always been like that. I have been beating my clutch into the ground for 10k Mi now.

Have you had a crash or anything? Any bent handlebar parts for any reason or tight/pinched lever bolts or pinched cable or something?

Good luck in your detective work. When you figure it out I'm sure you'll wonder why you didn't see it sooner. Maybe it just needed some lube or the return spring is going out or something.

DaBlue1 · August 16th, 2011, 11:11 AM

Is your clutch perch in the right spot? Having it in the correct spot on the handlebar can lengthen or shorten the cable.

headshrink · August 16th, 2011, 11:15 AM

Quote:

Originally Posted by ninja250

Sounds weird, man.

You dive in the clutch yet to see what's poppin'?

Is it the oil you are using or something?

The clutch is way out at the end of the pull on this bike for me currently.. but I think it's always been like that. I have been beating my clutch into the ground for 10k Mi now.

Have you had a crash or anything? Any bent handlebar parts for any reason or tight/pinched lever bolts or pinched cable or something?

Good luck in your detective work. When you figure it out I'm sure you'll wonder why you didn't see it sooner. Maybe it just needed some lube or the return spring is going out or something.

No crashes. I just so stumped because this is on my NEW-ish engine, but also did it on my OLD one.... that is why I ordered a new cable. I do a LOT of engine braking, which could account for my clutch on the old one wearing, but I have ridden this engine only for about 2 days! I was using Rotella T6 on the old one, but am using walmart dino as break-in oil on the new one. If it were not a new engine, I would just assume the clutch was going... since I don't know the history of the engine, I do have that doubt, but in a thousand miles!!!??? I won't open the clutch cover until I confirm a new cable won't work.... it isn't worth wasting a gasket for, unless I have to.... not to mention all the things I have damaged in the past year trying to be a brave little mechanic. It is likely unrelated, but I also have that other thread open on the whine.... just mentioning it incase some knows of some bizzare relation that isn't obvious.

headshrink · August 16th, 2011, 11:20 AM

Quote:

Originally Posted by DaBlue1

Is your clutch perch in the right spot? Having it in the correct spot on the handlebar can lengthen or shorten the cable.

Interesting thought, that didn't occur to me.... but, yes it is in the correct spot. I just ran out to double-check.

Alex · August 16th, 2011, 11:23 AM

Quote:

Originally Posted by headshrink

I just ran out to double-check.

Did you run back as well, or was it more of a saunter?

headshrink · August 16th, 2011, 11:26 AM

Quote:

Originally Posted by Alex

Did you run back as well, or was it more of a saunter?

I ran... don't have the confidence at the moment to saunter.

DaBlue1 · August 16th, 2011, 12:03 PM

Quote:

Originally Posted by headshrink

Interesting thought, that didn't occur to me.... but, yes it is in the correct spot. I just ran out to double-check.

You can always try to micro-adjust it by moving the perch and the angle of the lever. I found when I rotated my lever up the cable got tighter, so I put it back down a bit.

randomwalk101 · August 16th, 2011, 12:06 PM

headshrink,
you have ALL kinds of problem man...maybe you should just "ride it".

headshrink · August 16th, 2011, 12:14 PM

Quote:

Originally Posted by randomwalk101

headshrink,
you have ALL kinds of problem man...maybe you should just "ride it".

I would love it.

August 15th, 2011, 09:48 PM	#1
headshrink ninjette.org certified postwhore Name: Bob Location: CA Join Date: Dec 2008 Motorcycle(s): '08 Ninja 250r, '14 CBR500r Posts: A lot.	New engine, new clutch problem I'm starting a new thread on my [new] clutch problems, because it is now on a new engine (1.2K miles). I want to cry. I am now having the SAME problem with the clutch on my new engine, that I had on the old one The friction point is all the way out, and the cable has a ton of slack... How on earth can the new clutch in the new engine have the same problem as my old clutch, in my old engine. The only part that is the same is the clutch cable. I see zero signs of damage or fraying. I don't think it could be too stretched, because if I don't loosen the heck out of it, the problem gets worse. If I adjust the cable the way it is supposed to be, my hand won't even open wide enough to release the clutch smoothly. Since I got the engine from a 2010 salvage from an ebay wrecker, I don't really know the history of the engine, but it sure was clean, and had no visible signs of damage. I also have another thread open about a whine.... the current theory I am chasing down is possible an over-tight cam chain. With 1.2K miles, it SHOULDN'T have had the valve cover off, so it probably didn't have botched work for the cams or valves. I really don't even know what to think anymore. I don't know what to do, but cry... __________________________________________________ Honda Interceptor VFR800 DLX (2014, 8th gen) Honda CBR500r (2014) - FOR SALE Kawi Ninja 250r (2008) - Restored and passed-down within family, only to be abandoned

August 15th, 2011, 10:23 PM	#2
Skippii Milkshake Drinker Name: Skippii Location: Richmond, Va Join Date: Aug 2011 Motorcycle(s): 2007 Orange DRZ400-S, 2005 Ninja 250 & Custom Thundercunt Dirt Chopper Posts: A lot.	Is the clutch fully engaged with no slipping without a cable? If so, then the problem is the cable/lever/adjuster. __________________________________________________ "What a sweetheart."- ninja_sleeper to me

August 16th, 2011, 05:25 AM	#4
dubojr1 ninjette.org certified postwhore Name: Jason Location: Jacksonville, Florida Join Date: May 2010 Motorcycle(s): 09 Ninja 250R SE, 07 Honda CRF230F, 06 Honda CRF150F Posts: A lot.	Keep us updated Bob. __________________________________________________ 09 250R SE: Paying it forward one post at a time! Don't forget to add yourself to our Member Map

August 16th, 2011, 10:51 AM	#9
ninja250 You are sleeping Name: Casey Location: LMFAO!!! Join Date: Nov 2009 Motorcycle(s): 2 Posts: A lot.	Sounds weird, man. You dive in the clutch yet to see what's poppin'? Is it the oil you are using or something? The clutch is way out at the end of the pull on this bike for me currently.. but I think it's always been like that. I have been beating my clutch into the ground for 10k Mi now. Have you had a crash or anything? Any bent handlebar parts for any reason or tight/pinched lever bolts or pinched cable or something? Good luck in your detective work. When you figure it out I'm sure you'll wonder why you didn't see it sooner. Maybe it just needed some lube or the return spring is going out or something. __________________________________________________ <Yeah, it's a 250. LMFAO! Weaksauce

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August 16th, 2011, 08:21 AM	#6
Jinx250 Smoker Name: Bob Location: SoCal Join Date: Dec 2010 Motorcycle(s): Guess.... Posts: 556	Where in CA are you?

August 16th, 2011, 12:06 PM	#16
randomwalk101 self wrencher Name: john Location: houston Join Date: Dec 2008 Motorcycle(s): 08 250r and 07 600r Posts: A lot.	headshrink, you have ALL kinds of problem man...maybe you should just "ride it".