Clutch cable miracle!

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I have just returned from another bedding in run with my recently resurrected 650ss bitsa. I was making progress in top gear on a nice straight road when I noticed extra slack in the clutch cable. The cable still operated the clutch but I eased off all the same. A couple of pulls later the whole thing was loose and no clutch was available. The lever was flapping about and I thought the cable had snapped. This was a worry as it was only 150 miles old.

Anyhow - I managed to limp home as the roads were quiet and the junctions clear and I only had to push the last 100 yards or so. Onto the bench she went and long story short the cable is not snapped and to be seems intact. It doesn't even seem to be stretched.

It's a miracle!! Apologies for the clickbait by the way....

The clutch itself is a standard chain drive primary unit and was adjusted correctly (IMHO) as per the manuals. In use the 'bite' point was within the first inch of pull which includes the 'slack' built into the pushrod adjuster. Whilst heavier then I'm used to on more modern machines, was acceptable at this stage in the bikes resurrection. I've also been having issues finding neutral which means I have been holding the clutch in at junctions etc.

The cable is now off the bike. It came from AN and there are two inches of cable visible from the end of the ferrule to the first part of the barrel when the nipple is tight to the thread. The only work on the bike recently was to tighten up the primary drive chain which was too loose/noisy. Other than that this is the first clutch related issue so far. At least today most of the oil stayed where it should so progress is being made!

Any ideas? Is it sensible to continue to use the cable for example?

Thanks for your time

Kit

Attachments

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It's just possible...

... that the pushrod has softened and worn excessively. Alternatively the adjuster on the clutch pressure plate may have come loose (probably more likely in fact).

It must be clutch week as I was out on my BSA/Suzuki hybrid on Friday and the handlebar end nipple pulled off - to my great embarrassment as I'd made the cable! It's the first one I've had do this despite fitting dozens over the years. I was a few miles from home so called Britannia who sent a great big flatbed to pick me up.

The wait wasn't too bad - a couple of riders of modern bikes stopped to see if I was OK, and a passing pedestrian was very interested in the bike. He had a Trident at home but I forgave him that.

Have you looked at the nut…

Have you looked at the nut and adjuster fitted to the clutch pressure plate as it sounds like it has come loose.
Neutral hide and seek can be down to the clutch not pulling off square, tangs on the plates having "ears", basket worn in a similar fashion along with the plates themselves.
All these items may need addressing to have a smooth clutch action.
You could try a thinner primary oil too.
One other point is to check the chain tension is not too tight.

Thanks for the input. OK…

Thanks for the input.

OK. After due puzzlement and looking at the AN pictures of the cable, I've refitted the cable using a more sympathetic cable run and allowing for better curves. This seems to be better set now.

The nut and adjuster were in place (my first thought too) and the pushrod also looks fine - this was also a new item from AN so can't think this was the issue. I forgot to mention that I have new plain plates on the bike, new 650ss springs and that the clutch basket is in relatively good order. The driving plates were ok and I've not noticed any slipping. If anything there was a slight bit of drag on the clutch earlier today. Primary chain is set at 3/4 inch of movement and doesn't seem too tight. The clutch is back at full extension so I'll need a new primary chain at some point.

After refitting the cable the clutch action seems lighter now which is weird. In fact it's all a bit weird to be honest. Only thing for it is to have another run out at the first opportunity, but not to far!

Clutch centre nut

Are you sure the clutch centre nut has not come loose?

Symptoms are very like my own where this happened. OK, it was on a rotary.

Peter

I'll check that to be…

I'll check that to be certain but don't think so - I'll let you know soonest....

No - the clutch centre nut…

No - the clutch centre nut is good and tight. I remain confused and puzzled

Other Possible Issues

There might be problems at the actuator end of the gearbox mainshaft.
The shaft nut may be coming loose or the actuator locking ring unwinding.
Also the actuator arm can sometimes slip and drop down off the ball bearing.

actuator

Everything seems in place -…

Everything seems in place - the actuating arm remains in the correct position, remains solid and has not moved around - i.e. it remains in line with the cable The ball bearing also seems engaged.

I'm wondering if the cable jumped out of the adjuster on the handlebar under tension but at the time there was zero pull on the cable and it was flapping about like the cable had been cut.

The only way to be 100 percent certain of course would be to a. Strip off the chain case and the clutch (again) and b. Open up the gear box and check the actuating arm - but it does seem fine when viewed through the the inspection 'hatch'. The clutch and cable seems fine now it's been refitted.

I'l give her another run soonest and report back.

Ferule movement

Check that the cable outer end ferrules are crimped securely. Maybe either or both were not secure until the weight of the clutch pressure squeezed them into place.

That's exactly what I was…

That's exactly what I was going to suggest. I've had the cable coming out of the throttle cable adjuster under the tank once, when installing a new cable. Didn't notice that, as I was working blind. After a while, I suddenly had loads of play on the cable when the cable popped back. A ferrule (I'll forget that word again) could do the same.

Update & Thanks

Thanks for all the pointers. Just returned from a 40 mile round trip with no issues - other than rider errors anyway. The clutch cable is much lighter and easier to use and the bite point is just right. As an added bonus neutral is much easier to find so sitting in traffic lights is much less stressful.

I can only assume the original cable run was tight somewhere. On inspection there is some scratching on the outer cable about 8 inches from the gearbox end. The ferrules also might not have been properly bedded in. Time will tell but the set up as things stand is pretty good and certainly much lighter than of old. My left hand is very happy.

On to the next thing on the list!

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