Topic: How To? Routing Clutch and Throttle Cables...

[Dave-and-his-550]

Dave I don't think you mentioned it, but are the dots on the arm and clutch cover lined up?  You might want to start there and then adjust the clutch if you haven't already.

Actually no, they are not lined up that well...I would have to lower the lever down some for them to line up, but then it will be in that position before where its not even disengaging when I pull the hand lever. The clutch lever would feel very slack.

So, I just did what laminar said and that was to adjust it to the point where the lever wont move up anymore by hand force. There I found it actually disengaged the clutch (But I'm not sure how well) when I pulled the hand lever, with a lot of resistance.

Maybe I should reconsider the routing. The bars are lower, so I might need to route in a new fashion?

But in the end, the two lines on the clutch cover, and the lever cannot seem to line up properly. I did take apart the spring mechanism inside the clutch cover when I went to polish it up, maybe I assembled it wrong?

[fastbroshi]

   If memory serves me correctly, I don't really think you could put it together and have it seem out of adjustment as your is.  I took mine apart and put it back together so I'm pretty sure. 
   It has that spring actuated cam that if installed incorrectly won't do anything.  Your problem sounds just like the one I had after I put mine back together.  You have to adjust everything out, plenty of slack on the clutch cable.  Line up the dots using the slotted screw at the bottom of the clutch cover.  What that does is set the distance the arm sits away from the clutch center.  With the dots lined up, I'm pretty sure it sits just off of the center of the clutch rod (incorrect term?) that when pushed (when you pull the clutch lever), separates the clutch plates.