Super heavy clutch pull (Snapped clutch cable)
Hi all,
Had my SV for a few years now and it's always had a very heavy clutch. Changed and adjusted the clutch cable many times with no change. Adjusted the worm gear many times with no change. When the cable is routed through the bike I can easily pull it back and forth by hand so I don't think it's kinked anywhere. When fully installed it snaps back fine and has the correct free play/travel etc. This morning my clutch cable snapped, it was less than a year old. Could anyone suggest what to investigate to solve this? Been wondering if someone put in aftermarket springs in the past, but would they make it this heavy? (Takes 2 hands to pull in when cold normally) Cheers |
Re: Super heavy clutch pull (Snapped clutch cable)
This page should help,
https://cx500.000webhostapp.com/SV650ClutchLifter.html When getting a new cable be careful to get one with the correct Radius pipe at the Lever end. :) |
Re: Super heavy clutch pull (Snapped clutch cable)
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To be 100% sure I've ordered a different one and will fit it as the replacement to the snapped cable. I've replaced all the ball bearings in my worm gear and it seems very smooth with no noticeable resistance so fairly sure that's ok. Will be taking the cover off to have another look later today. |
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Re: Super heavy clutch pull (Snapped clutch cable)
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I have previously tried the slinkyglide cables and wasn’t impressed; it felt heavy and gritty! Incidentally, the gixer cable is still on my curvy sport and working fine. |
Re: Super heavy clutch pull (Snapped clutch cable)
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Re: Super heavy clutch pull (Snapped clutch cable)
So bit of an update, went to fit the replacement clutch cable I ordered and deliberately routed it outside the frame to ensure kinking wasn't an issue. Set it all up but found that the inner cable is too long meaning the tension adjusters couldn't take all tension out the cable.
Went to adjust the worm drive/lift arm by setting all tensioner to 0 and screwing in the central grub screw until I felt contact with the push rod, undid a quarter of a turn. Locked that off then used the tension adjusters to try and get the lift arm at the correct angle as specified by Haynes. Again, I couldn't get enough tension in the cable to lift the arm to the correct angle and get it to engage the clutch enough. I ordered a supposedly oem cable specifically for the S model I've got and I've had a similar issue in the past with basically every other cable. The bike has handlebars conversion but that shouldn't affect the inner to outer cable length ratio which determines tension. It also has aftermarket levers, wondering if the mount for the cable nipple on those is too close to the outer cable? Did a bit of further inspection on the worm drive onwards. Found the push rod to be clean, sliding freely and straight. The worm drive didn't have any ball bearings missing and was relatively clean. However I did notice some play in each part as seen in the videos linked below: https://youtu.be/0HlIIZ6G6NU https://youtu.be/yGsEeTaKsrI Not sure if this play is meant to be there or what effect it could have on the system, anyone messed with their worm drive and found this before? I did manage to rig the cable so it's disengage the clutch mostly and found it to be lighter but still relatively heavy. Wondering if the clutch has aftermarket springs in still.... |
Re: Super heavy clutch pull (Snapped clutch cable)
Always felt the clutch was slightly heavy on my SV when I had it, but put that down partly to the short levers.
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Re: Super heavy clutch pull (Snapped clutch cable)
I can operate my 99 Curvy clutch lever with 2 or 3 fingers so they can be set up nice. Something is not right :(
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