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

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?

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

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.

What makes this forum so great is all the updstes from people...:thumbdown:

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

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.

Time to remove cover, you need to check inside what happend when arm was detach from cable.

some videos showing the new clutch cable fitted and movement of the lever and the arm


https://youtu.be/RJeK7rJTu1s





https://youtu.be/gERJh4FED5Q

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..

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.

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

Clutch is ok then, slightly drag is same on mine now when its cold oil thicker, let it get hot and try again.

Check the switch for the stand, maybe relay dont get switched. Also measure the wire from clutch handle switch, seems like relay problem.

ok thanks never thought about the switch being an issue, makes sense

Looks like you are selecting a gear with the engine running and the sidestand down. That combination has a safety feature which cuts the ignition. You are supposed to only be able to select a gear with the sidestand up, when engine is running.

I didnt notice its so dark at the stand, but if thats the case its not possible. I dont understand is this first day with the bike? Thats common on all newer bikes not able to run with sidestand down...

im also a bit confused about what is the current problem


original title is:


"4pt new clutch cable now can't declutch"

so now problem is engine dies when you put in gear?

not the same problem.... a bit confusing really

Guess he found out how to get the sidestand up:D

I just skimmed this thread, and without diving in to details, I wondered if he has the right cable? Always worth comparing new cable to old before installing, just as you put the new cable on and keep the old for a spare when travelling - because you KNOW it's the right one.

Yes he wrote about testing new and old, problem was the sidestand was left down and bike wouldnt run when put in gear...Never a clutch problem!

https://ibb.co/fGjNZ0C
https://ibb.co/WkXQ82N


Thanks very much, bike sorted now. The side stand switch connection (the blue one ) hadn't been cleaned last time I did all the others. The clutch lever contacts were fine (green). Bike sorted now, wouldn't have thought of that. Thank you. Any xt600 riders North Kent? Saw a xt500 yesterday at the Herne Bay bike park, don't know if he's on this forum

Well just dont forget to kick up sidestand next time you are testing after repairdoh

Entirely plausible explanation. Been riding a C70 all summer so learned some sloppy habits. Thanks all :oops2:

well, you definitely owe us all a beer..... for trying to help you solve a non existing problem... :oops2: