Topic: Stiff clutch cable

[yogi]

This topic has been covered before....

http://forums.sohc4.net/index.php?topic=14273.0

But I wanted to ask a follow-up question, and since the original topic was so old, I thought I would start a new one.

I just bought a 1972 CB500, clutch cable was super stiff (can barely pull it). I took apart the lifter, cleaned and greased it, and replaced the cable. Still stiff. I then found the above topic and everything pointed to the lifter rod, which is impossible to find. I think everything else (i.e., cable adjustment/routing) is set up fine as the clutch is easy to pull if the lifter rod is out.

I pulled the rod and it looks fine; not bent or cracked, 256mm long, the little dimple where the ball fits is centered.

My question is, could it be anything else, before I go to the expense of having a lifter rod made? I am wondering specifically if there is anything on the clutch side that I should check, such as the springs. Also, I noticed that I can't push the lifter rod in by hand, should I be able to do that, or would normal resistance be too strong?

Thanks; feeling kinda frustrated and want to get this new to me bike on the road!

[Mantree]

Get a cable lube tool and a can of spray lube.  Even if it don't fix it its a good hung to have around to hit your cables with during your annual tuneup.

[TwoTired]

The more bends in the cable,the stiffer it operates under load. Small bend radiuses also increase resistance.

Cheers,

[Deltarider]

If it's a OEM cable, lubing won't help as it is teflon lined. They don't need maintenance and will do 50.000 kms easily. You may want to read this: http://forums.sohc4.net/index.php/topic,165583.msg1914790.html#msg1914790 .

[yogi]

I'm fairly certain it is not the cable or routing. If the lifter rod is out, the cable resistance is fine. Therefore, I don't think it is a problem from the lever, through the cable and lifter. The stiffness happens after that, so it seems it must be either the rod itself, or somewhere in the clutch (springs, plates not pulling apart, whatever). Being sort of a newbie, I'm not really sure what could cause this problem from the clutch side of things.

[Deltarider]

My question is, could it be anything else, before I go to the expense of having a lifter rod made?

No need for that. A rod is a rod.

I am wondering specifically if there is anything on the clutch side that I should check, such as the springs.

I don't think so, unless the bike has done many, many miles and PO maybe mounted aftermarket springs. Have you tightened the 4 bolts that hold the cover well enough? Did you actually run the bike and have you shifted gears a couple times? Could be done on the center stand. If bike has stood for a long time, clutch plates could be sticking and need to come free by some action.

Also, I noticed that I can't push the lifter rod in by hand, should I be able to do that, or would normal resistance be too strong?

The latter, it's absolutely normal that you can't push it by hand. Did you say you had the lifter apart and greased it? Did you set the play of the lifter as prescribed? BTW, forget about the play at the lever as prescribed by Honda, but follow Hondaman's advice instead in: http://forums.sohc4.net/index.php/topic,165583.msg1914790.html#msg1914790

[Bodi]

You've covered the common problems. You can lube a teflon cable, it doesn't hurt. "Normal" cables need to be lubed. The most common cause for hard pull is the cable routing. Try taking the cable out... just let it hang in the open with no sharp bends from the lever to the engine. See how stiff it is then.
The Honda service manual should have a detailed diagram showing where they routed the cable, that is probably the best possible way.
If it's still a super hard pull with the cable loose, you probably have stronger aftermarket springs installed.
The 500 has a fairly strong clutch pull at best, don't compare these bikes with modern sportbikes that mostly have very light pull hydraulic clutches.

[evinrude7]

You've covered the common problems. You can lube a teflon cable, it doesn't hurt. "Normal" cables need to be lubed. The most common cause for hard pull is the cable routing. Try taking the cable out... just let it hang in the open with no sharp bends from the lever to the engine. See how stiff it is then.
The Honda service manual should have a detailed diagram showing where they routed the cable, that is probably the best possible way.
If it's still a super hard pull with the cable loose, you probably have stronger aftermarket springs installed.
The 500 has a fairly strong clutch pull at best, don't compare these bikes with modern sportbikes that mostly have very light pull hydraulic clutches.

i have a 750.  not sure the difference in clutch pull but i agree with bodi.  it's not a modern bike.  lube the cable, route it correctly and adjust the clutch.  ride for a while and you'll get used to it.  before you know it, you'll forget it was ever an issue. 

[yogi]

Thanks for all the replies. I have not ridden the bike since changing the cable and whatnot. I will ride it some and see if the clutch loosens up to the point where I can ride it comfortably. Maybe I need to just build up some strength in my left hand. My right hand gets most of the exercise now, but that has nothing to do with motorcycles...