Help with clutch

[flyingmech]

Hello guys, have purely joined the forum to ask for technical help. Have just fitted new clutch plates, clutch cable and clutch mechanism. Along with new oil to my 1999 sv650.

however since doing this have had a strange problem, the clutch lever seems to go very stiff when engine is cold, and then slackens off when the engine warms up (so I have to adjust it whilst riding). Then when I park it up and the engine goes cold again it all stiffens up.

Can anyone shed some light on the situation?

Help appreciated,

Dan

[Bibio]

clutch cable routing or you have put the clutch mech spring retainer on the wrong way.

did you soak the clutch plates in oil overnight before installing them?

[flyingmech]

I did soak the plates overnight. Will check the cable routing as that seems like one of those things easily done wrong.

Should state that the clutch mechanism wasn't brand new but a second hand one from eBay, so may be that.

[flyingmech]

Which bit do you mean by clutch mechanism spring retainer? As the worm drive bit would be very wrong if it was on wrong way

[Bibio]

a lot of people end up putting the spring retainer under the main body of the worm drive, it should sit on the top just under the bolt heads.

the worm drive is the last thing you want to be buying second hand.

[flyingmech]

That's cool then, so I have that on correct. Will try putting old one back on and see if that makes a difference and also have a look at cable routing.

Any ideas on why it is doing wjat I described?

[Bibio]

it could be a number of things. i would like to know what you mean by lever going very stiff?

less play or just harder to pull? if its just harder to pull does the lever spring back just as easy when its cold as it does when its hot?

[flyingmech]

It basically loses all of its free play (so much so the bike just stalls) and becomes stiff to pull in when cold, then as I ride it it the lever loosens up, and Ih have to wind out the handlebar adjuster to take up the excess slack and get correct amount of freeplay. Then I leave it over night, engine cools down and then the lever is stiff again.

[Geodude]

Did you adjust top and bottom? Lever and worm drive? Loads of how to's on the org. HTH

[flyingmech]

Yes, I adjusted both bottom and top adjustments

[Bibio]

did you adjust the pushrod on the wormgear? which is not the top and bottom ones on the cable.