Hey guys,

Just finished rebuilding engine (first rebuild, used info from this site) everything has gone well so far. Only thing is, clutch cable no longer reaches.. Im a little bit confused as to whats happened, it was fine when i took it off. The mount bracket is in the correct location and i have it connected at lever end with full slack, but does not reach other end (engine end) i can get it on if i hook both ends of cable on before doing it up at the mount, but then its way to tight. Do i need a new cable (I thought they stretched over time not shrunk? O.o) or am i doing something stupid? (sorta assuming the latter) its the same cable as i was using before so should be the right length, and seems to work properly, how do i adjust this properly? i must be doing something wrong..

Thanks

Edit: Oh and currently at the engine end its adjusted right up against metal elbow and at lever end right up against lever.

the cable is the same. the clutch lever/perch is the same? assuming so, the only variable is the engine build. is the clutch actuating shaft installed properly? does it actuate the clutch rod properly? did you check during installation of the clutch?
_________________
MC21R9N track
MC18R2J track
CBR954
CR250

oh sorry, only rebuilt top end. I took the engine out before hand because i was expecting to need a full rebuild (even brought a new crank), turned out the front cylinder was seized, so replaced front cylinder, both heads and pistons, rings etc. Started bike up after everything is back together and ran nicely.

the spring hook thing at the engine end seems to work properly without the cable on. Have another engine to compare it too. I'll Play around some more and see what i can do.

Flip the clutch bracket on the engine around? I've been guilty of putting it on the wrong way around myself! Changes the position of where the cable passes through the bracket quite markedly.

ok so i have played around a bit more. the bracket was on right, still have had no luck. i moved the bracket a bit closer now the cable reaches and somewhat works. clutch is not engaging tho, even if i manually pull on the engine end (as if clutch lever was in) so im a bit confused as to whats going on, as it was working before and i didnt go near the clutch.

it happily changes through the gears without the clutch (not running)

Is there any quick tests i can do to help diagnose this a bit before opening up the clutch? I have a spare clutch (in another engine) so if anything is damaged i should easily be able to replace it. have never worked on clutch before tho and would rather not open it up if something else is causing the problem. the spring lever at the engine end seems to works well, points the right directions, moves the right amount, springs back, just doesnt seem to engage the clutch.

If something is in fact wrong with the clutch how would this happen? bike locked up at about 100km/h put clutch in to unlock everything, worked then. sinse has been sitting around untouched.

is there anything i needa do sinse i fully drained oil? (has oil now obviously but sat for a while without any)

Is the clutch arm that the cable connects to the right way around. Does the clutch engage with no clutch cable ?

How long has the bike been sitting, clutch might be stuck, ie; plates stuck.
_________________
Proud Father of , 05 ktm 400exc supermoto 2018 honda crf rx supermoto

thanks for the responses,
yep the clutch arm appears to be facing the right direction. if i pull on the arm well push from left side with my hand, the clutch still doesnt engage.

the bike was sitting for about 6 months. If the plates are stuck, how do i unstick them? that sorta makes the most sense at the moment.
if i start the bike up and leave it running and repeatedly try to engage and disengage the clutch will it come lose or is that likely to break something?

thanks

Does the bike run? If so, start it up and warm it up to operating temperature. Pull the clutch in and out and see if it frees it up. This happened to me with an engine that had been sitting. When everything got hot and loose all worked fine.

yip bike runs. gonna try that first thing in the morning. WIll post back with results. pretty sure thats the prob and that this will fix it

yep the clutch arm appears to be facing the right direction. if i pull on the arm well push from left side with my hand, the clutch still doesnt engage.

You mean the clutch doesn't disengage.

If clutch plates are stuck you can start the bike, push it along and shift into first. hold the cluth lever in whilest doing so. get on and give it a little gas with the clutch lever held in. it should disengage. don't mean to be overstaing the obvious. sometimes you just can't tell from the written word.
_________________
MC21R9N track
MC18R2J track
CBR954
CR250

I think you've turned the lever on the engine the wrong way around.
Meaning you've pushed it towards the front of the engine towards the cylinders/front wheel.
It needs to be turned towards the rear of the engine, the cable should head diagonally backwards from the adjuster bracket on the right side of the engine.
The main lever on the engine should be pointing backwards towards the rear of the engine.

Clutch is working now, plates were stuck. cable is still currently mounted slightly wrong but it working. Gonna go have a play now that the clutch is working properly.

Went for a ride. ran quite nice. A few problems i need to fix tho, need new battery, one of the powervalves is sticking, and temperature gauge does not seem to work, should be running real nice after that

Thanks for all the help.

Good to hear you got it sussed. I had that happen to my old escort back in the day once.
Where abouts in NZ are ya?

Have taken for a few rides now, everything is well. needa tweak a few things here and there but that never really ends haha.

{.blank}GoD, Living in hamilton at the moment. Christchurch? ouch.. hope things arnt going to badly for you down there. If your ever up these ways flick me a msg, will go for a ride.