Stiff Clutch

[Snakeoil]

The little Green HONDA 300 SCRAMBLER OWNERS MANUAL shows 0.8 to 1.0 inch of play at the Ball End before ya pull the cable. ....lm

That's interesting, LM. My CL72 service manual says 15-20mm (.6-.8 inch) for the clutch and 20-30mm (.8-1.2 inch) for the brake levers.

What year bike is that for? The reason I ask is I'm wondering if it is for later Type 2 forks. If so, is there a fork oil capacity in that manual?

Thanks,
Rob

[56_oval]

The little Green HONDA 300 SCRAMBLER OWNERS MANUAL shows 0.8 to 1.0 inch of play at the Ball End before ya pull the cable. ....lm

That's interesting, LM. My CL72 service manual says 15-20mm (.6-.8 inch) for the clutch and 20-30mm (.8-1.2 inch) for the brake levers.

What year bike is that for? The reason I ask is I'm wondering if it is for later Type 2 forks. If so, is there a fork oil capacity in that manual?

Thanks,
Rob

My manual says 3/4 to 1 1/2 inches. Either way, I think you guys are probably right, so I ordered a set of stock style levers. I'll try them and see what happens.

[56_oval]

Ok, so I go the stock levers today, well somewhat. The guy sent me two right handers instead of a set. Either way I measured them next to the ones I have and there MAY be 1-2 mm in difference. I don't know if this is enough to cause a problem or not. I haven't put em on yet cause I have to take the wiring back out of the bars first. I may try tomorrow.

[56_oval]

Ok, so I measured the travel on both levers. The "stock" AM levers pulled a total of 16.6mm and my Tomaselli levers a total of 16.1mm. Do any of you think that .5mm will have any adverse affect on the clutch? I'm thinking I need to take the clutch back apart and check it for warped plates.

[56_oval]

You cannot just put any set of levers on any bike. You have to be sure that the cable pull is the same for the new levers and the stock levers.

My guess is your new levers have the hole for the cable slug much closer to the pivot hole than your OEM levers.

regards,
Rob

I checked that Rob, but the new levers are actually further apart than stock...

[GeorgeP1111]

The following measurements are taken with a lever free play set at 15mm.
Dt = 17mm*

I'm not clear on your measurement. If the free play is 15mm and the total "Pull" (Dt) is 17mm then does that mean you only have 2mm of cable movement to actuate the clutch?

Actually, the 17mm is the figure I'm interested in. That should equal the amount of movement at the end of the cable connected to the Clutch Lifter. I have my motor on the bench now and I want to see how much my clutch is moving when disengaged (ya I know... I could have checked this when it was on the bike... I didn't). 17mm of movement on the Clutch Lifter will show me how much movement there is on the push rod and that is how much my pressure plate will move.

I too suffer from the "Sticky Clutch Syndrome". I have read just about everything there is here on this subject and have checked/tried all the recommended items and the problem still persists. It seems like it comes down to the thin film of oil between the plates.

tnx
George

[56_oval]

I measured with a cable not attached to the bike at the opposite end fron the lever and I get a total cable movement of those measurements. So, I don't know how much is left after you take free play into account. I really want to figure his out cause I want to ride!!