So, my bike fell over in the garage and the crank cover cracked. I replaced it and installed a gasket in place of what was just gasket maker before. Changed the oil and all that good stuff including a new clutch cable. But now even with the perch and the adjuster on the engine case backed all the way out, the clutch will just barely fully disengage. Any ideas as to what happened, the previous cable acted the same when the new cover was put on. Before the fall, the bike shifted great.

 

Did the clutch basket get damaged at all? And what do you mean by backed all the way out? On the case side you should take up all of the freeplay on the lever (Crankcase Lever) and then tighten just slightly past the freeplay. Your handlebar lever freeplay on the control lever should be 0.4-0.8 in at the Ball on the end of the lever.

 

My lever on my 90 doesn't have much free play either, and I have it backed all the way out as well.

 

If you thread the adjuster out so you are pulling on the cable at rest,you have it too far out. There should be slack or free play in the cable.

 

Freeplay is adjusted at the handle, not the case. There is no freeplay at the case.

 

ok is it because im new that every new page i go to i have to sign back in..... grrr. anyways, I dont know if there was internal damage when the bike fell over.

All I do know is that freeplay or not, the clutch will only barely fully disengage when I set it up the best I can figure. I have all but about 3 threads showing on the cable side of the case mounted adjuster and all but one or two threads showing on the perch adjustment. Sorry to mangle any terms, Im still new to bike terminology.

 

Tighten the case adjustment more. See if it helps.