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1 Oct 2024
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4pt new clutch cable now can't declutch
hello
just changed the rusty cable on my 2003 4pt and now can not get any adjustment which allows me to de-clutch gears. just a simple swap over of cables and now doesn't seem like the clutch arm is doing anything. the clutch arm will move and is slightly sprung but that's it, won't get me out of gear.
there's a bolt head under the clutch arm, can't find anything online yet about what it is.
any ideas please?
ben
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1 Oct 2024
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that bolt is securing clutch arm in place.
clutch arm mustn't be "slightly sprung", when properly linked with basket through the push rod.
something like this - https://i.imgur.com/zyPRgVW.jpeg but the link is geared in xt's case.
maybe that push rod is fallen back inside the basket (not sure if it's possible) or otherwise not aligned with clutch arm?
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2 Oct 2024
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have you checked if cables (outer sheath and inner cable) are same length?
a difference of even just a few mm might throw you out of range at the adjusters.
the mech is NOT like N67 shows, it a geared system
the geared pull rod can not fall inside, so that shouldnt be the problem
the clutch arm rotates this part
https://images.cmsnl.com/img/product...00-01_eba8.jpg
the gear at the bottom of that part moves the pull rod
https://images.cmsnl.com/img/product...01-02_6449.jpg
maybe the images will help you understand what you are doing wrong.
hope you didnt dismantle the arm form the splined shaft, if you get ib ack on the wrong position, again, it will be impossbile to adjust
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2 Oct 2024
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I bet you have done wrong on the adjusters, you have one down on the casing and one clutchhandle. If you didnt adjust these correct its not possible to withdraw the clutch, too much slack cable.
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9 Oct 2024
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What makes this forum so great is all the updstes from people...
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10 Oct 2024
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agree with you but the world has changed since the days this was a busy forum more than 6-7 years ago
1st - general interest in enduros from the 80s-90s has gone down (unless its GS or XT500)
2nd - in all the forums of vintage japanese bikes i am in, there are less and less active members
3rd - bad influence of social media/facebook: people dont understand the community sense of a forum, many newbies thinks its just a place to ask one thing they dont know and then disappear without saying thank you
if you are lookig for more "action" the advrider xt600 section is just OK-ish, but one new post every month or so and mostly american riders.
tenere.co.uk, not great either.... good people but posts are splits into all the different models, hard to follow.
guess there must be a FB group but i dont have FB and hate how posts are totally disorgnized
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10 Oct 2024
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Thanks very much for all the replies.
I think the clutch cable isn't the issue as have adjusted it without slack and not too tight. Swapped the cable just in case but no difference.
Haven't taken the clutch arm off, just the cable.
The clutch arm moves about 50 degrees. Doesn't feel like it's doing anything constructive, just comes to an abrupt stop when it's pulled. Will take a photo tomorrow of it in this position.
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10 Oct 2024
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Quote:
Originally Posted by stillben
Thanks very much for all the replies.
I think the clutch cable isn't the issue as have adjusted it without slack and not too tight. Swapped the cable just in case but no difference.
Haven't taken the clutch arm off, just the cable.
The clutch arm moves about 50 degrees. Doesn't feel like it's doing anything constructive, just comes to an abrupt stop when it's pulled. Will take a photo tomorrow of it in this position.
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Time to remove cover, you need to check inside what happend when arm was detach from cable.
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11 Oct 2024
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Quote:
Originally Posted by stillben
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Nothing wrong its moving enough, maybe just hang on clutch plates. Tell us more what happens when you move bike in gear, put in neutral and move into gear moving bike, worn out slipping? Hard to tell with so little info..
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11 Oct 2024
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Quote:
Originally Posted by xtrock
Nothing wrong its moving enough, maybe just hang on clutch plates. Tell us more what happens when you move bike in gear, put in neutral and move into gear moving bike, worn out slipping? Hard to tell with so little info..
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fine in neutral, can move it
in first with cluth pulled in it is possible to push it slightly, there is plenty of resistance, back and forth a little
but# trying this without clutch in first is impossible for me.
if i have the bike running and drop it into first with clutch in it will stall, haven't managed to do this with the bike moving yet, will try this next, see if it will release the plates a little.
could try similar with raising it on a block.
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11 Oct 2024
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video clips of in and out of first
putting into first with revs around 2,000 and clutch lever all the way in
https://youtu.be/Iv5gMIjUBIw
rolling back and forth with engine off and clutch lever in and then with clutch leave left out
https://youtu.be/itlp5mq0wM4
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11 Oct 2024
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Quote:
Originally Posted by stillben
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Clutch is ok then, slightly drag is same on mine now when its cold oil thicker, let it get hot and try again.
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11 Oct 2024
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Quote:
Originally Posted by stillben
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Check the switch for the stand, maybe relay dont get switched. Also measure the wire from clutch handle switch, seems like relay problem.
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11 Oct 2024
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ok thanks never thought about the switch being an issue, makes sense
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