Hi All.I have a strange problem not sure if its clutch related or not.Hoping someone can help.96 Roading. Started it in the garage yesterday and pulled out to the street to warm it up and couldnt get it in neutral.Also,bike felt like it was pulling with lever pulled against the bars.Shut it down and finally got in neutral.Warmed it up and took off down the road.Had a real hard time getting in second.it was very difficult to shift.Came to a stop,down shifted and took off again happened again.Took off a 3rd time and all was well.Shifted fine for the rest of the day.No problem shifting or finding neutral whatsoever. My first thought was a ball and ramp issue.I loosened the cable,dumped the fluid and pulled off the trap door and inspected and things look good.Going to grease and reinstall today.My next step is to readjust clutch.Am i missing anything??.Primary and trans oil level is good and not overfilled.Primary chain adj seems fine..Im usung belray 80/90 in trans and hd formula + in primary.

 

How old is the clutch cable and ramp assemble

Adjustment then cable itself then ball n ramp. are my thoughts

In that order also

WP

 

Cable just a couple years old.One thing i did notice when i replaced it then was that the cable adj was pretty close to max in order to get the proper lever free play

 

Be sure the cable adjuster is fully collapsed and the lever is against the handlebar before adjusting the clutch center screw. (Yes, that does make a big difference). Back the center screw out no more than 1/2 turn from a solid touching, lock it down then adjust the cable.

It's totally normal for the cable adjustment to be near max, even with new cable or all new parts everywhere.

 

So a simple clutch adj might be the fix then?I guess the fact that it cleared itself after a short ride got me thinking it was somthing more serious I'll try the adjustment and see what happens.Its raining in my part of the world today so a good day to mess around in the garage

 

Yeah, do that and I think that'll get you good to go.

Another trick I found by accident and I've used it ever since - when collapsing the cable adjuster, pull the lever to the end of free play about every 2 rounds or so of the adjuster until it's against the bars. Continue till it's at least within a couple threads of "far as it will go" or totally collapsed.

With the lock nut backed off, run the center screw in till it touches, then continue another half round or so until you feel the lever move away from the bars a bit. Pull the lever gently a couple times. Then with a finger on the lever, back the screw off till the lever touches the bars. Turn screw and back in till it touches, then out 1/2 round and lock it. Adjust cable free play.

I don't know why or how, but I had one that was totally "right" but the engagement and free play was inconsistent while riding hot or cold. I did that and it was totally good from then on. So now I do that method every time.....

 

I will try that.Got the ball and ramp mechanism greased and assembled.I think I'll wait till tomorrow and get a new trap door gasket just i case.thks for the tip

 

If your clutch pack has a spring plate, I would check it. When mine came apart, the symptoms were very similar.

 

When you had the trap door off did you check the condition of the release bearing ? I had mine fail and was basically missing - I had issues with adjusting the clutch when this happened.

 

I didnt notice anything obvious inside the trap door but will look closer tonight before i install it.Picking up a new gasket today so its still apart.thks