Ok here's one for the books. I put a new clutch in and cable .. About 100 miles later I pulled up to a light pulled in the lever and the bike was jerking and trying to drag me forward. so i quickly adjusted the cable all the way out and it worked enought to get me home. Now we have had the clutch in and out about 5 times everything in the basket is new the fibers the metals the springs and the 2 washers that go in the basketalong with a new throw-out berring. Now when I pullin the lever, when its cold the bike goes into gear kinda hard makes alot of noise ect. And it releases way out like allmost at the top, with very little freeplay in the cable.After about 15-20 minutes of riding the lever pulls in real easy and releases close to the grip, with alot of freeplay in the lever? anybody got a clue or has anyone had this happen to the?? One of the 2 out of the 5 times it was apart it was done by a shop and none can see anything wrong..

 

I'd take this to the general tech forum for more opinions.
Wish I knew more about the clutch system, sorry!

 

all the sepecs are right on the componets?

 

what kind of oil are you using. if you're using synthetic or 20/50, switch to honda hp 10/40. also, are you using stock fibers or are you using aftermarket fibers. remember new fibers have a break-in period and if pushed too hard initially they will glaze over, givingslipping effect. to deglaze the fibers, hold the clutch in, putthe bike in gear and hold the front brake on, give the bike a little gas and release the clutch slowly until the bike almost stalls out. voila, plates deglazed,problem solved.you may have to do this often.

 

Did you look at the inner and outer clutch basket, really close?

After years of wear, these parts can develop grooves or notches where the tabs on the inside and outside clutch plates are supposed to slide on them. I had the clutch apart in my 96 about 8 times trying to diagnose a different problem. Some one helping me from a forum (maybe this one) had me check that out. I'm wondering if this is causing your problem.

By the way, mine was bad clutch springs.

 

Thanks to all who have replied ....

 

It sounds like it is a couple things. First, did you replace the cable with a Honda cable? It kinda sounds like the inner cable length is off. It also sounds like the cable is getting more pliable as the motor heats up. This could cause a lot of what you are describing.

I also agree that the oil sounds like itmight havea slipping agent in it, though it if did, you would not be able to rev through the power band without the clutches slipping. What oil/weight did you use? If the oil you used has a slipping agent, your organics are dead and should be replaced.

Short of anything above, I'd say to remove the judder spring, which is that odd, tapered washer that is the first thing slide on in the clutch basket just before the first organic. Then, replace the first organic with a normal sized one.

--Chris

 

One more thing: I feel your fustration. I hate screwing around with this stuff.

--Chris