Clutch Rod Adjustment Screwing In Too Much?

[CraiGDaniel]

I cannot place the nut on the clutch rod adjustment screw, as it winds in too far before it 'bites' leaving no thread to screw the nut on to.

Is this a problem ?

[speedfreek]

If you're talking about the clutch cable adjuster, you can tweak it at both ends.  At the clutch lever, and at the
engine case.  If one is in too far, back it out and put some slack into the other one.

TJ

[Dizzledan]

If it wont screw in anymore, that would mean something on the other end has shortened or worn down. Have you opened up the mechanism cover and pulled out the pushrod to see if it has broken off? Maybe time for a new clutch? Have you noticed slippage or is your friction zone moving around?

[CraiGDaniel]

Dizze, the bike recently has a new clutch basket and plates fitted, along with a new clutch cable.

THe pushrod snapped and that was replaced with a used one.

However it was about 2 months ago and its started happening now. The screw just doesnt bite until it's got no thread left, so i cant secure with with the nut.


ANy other suggestions?

cheers

[Kerry]

If you're talking about the clutch cable adjuster, you can tweak it at both ends.  At the clutch lever, and at the
engine case.  If one is in too far, back it out and put some slack into the other one.

TJ

+1

[Dizzledan]

How does the clutch lever feel? Is there any tension at all? Can you move the bike in gear?

[Precisi0n]

I'm confused.  Is the cable too loose or too tight?

From my experience with other bikes, new cables tend to stretch out for a period of time.  If it's too loose, adjust it on the engine side to take up the excess slack.

[Dizzledan]

Craig's problem is internally related. The clutch pushrod is on the left side of the engine.

[Kerry]

So, are we talking about assembly #24 in the diagram below?  (Specifically, items 25 and 26?)

   

[CraiGDaniel]

Yes kerry spot on.


25 is the 'screw' that you turn to adjust the pushrod. It is secured with a nut (26) however the pushrod is screwing in so far its almost flush and theres no thread to secure with the nut.

This is causing the pushrod adjustment to come loose with vibration over time and giving me lots of hassle as im having to constantly readjust clutch points etc.


I dont understand why it's screwing in so far

[gsJack]

Make sure there is plenty of slack in the cable when making that push rod freeplay adjustment so the lever inside is completely returned to it's stop.  Any chance you put a shorter allen screw in that location?  A good place to start would be checking the length of the screw and the pushrod before opening the other side again.  Was the replacement pushrod you put in the correct one?  Most likely something came loose after your clutch replacement a couple months ago.

[Suzuki Stevo]

Dizze, the bike recently has a new clutch basket and plates fitted, along with a new clutch cable.

ANy other suggestions?

cheers

Maybe, and that's a big maybe, could the clutch basket have been put together with more plates than required?? This would make the pushrod be farther into the engine than normal??

This is all I can come up with 

[CraiGDaniel]

Make sure there is plenty of slack in the cable when making that push rod freeplay adjustment so the lever inside is completely returned to it's stop.  Any chance you put a shorter allen screw in that location?  A good place to start would be checking the length of the screw and the pushrod before opening the other side again.  Was the replacement pushrod you put in the correct one?  Most likely something came loose after your clutch replacement a couple months ago.

Slacked the cable as much as possible - same thing.


The pushrod was given to me by a member of another forum from one of his training bikes.

Perhaps my first stop is buying a new pushrod ?

Cheers