super tough clutch

hey all. i have a 71 with a 75 850E motor. the clutch is crazy hard for me to pull in. i know that they can be stiff, but i cannot even pull it in with one hand ( & i cut metal for a living & am not the weakest girl around). any suggestions?
thanks a bunch.

First thoughts would be to check cable routing thoroughly.
1. Start at the lever all the way to the outer cover.
2. Pull the inspection cover and check that cam lever mechanism where the cable connects in the tranny isn't off kilter. If so.......
3. Pull the cluch adjustment plug on the primary and loosen the adjustment screw to help in reseting the cam lever mechanism on the opposite side. and if need.......
4. Pull the primary cover and go through the clutch. Suspect at this point would be a groove up clutch center. You will have to replace it if need and add some Barrnet clutch plates. Teflon lined clutch cables are out there too.

Hope this helps. Keep us posted

thanks & i'll let you know how it goes.

Here's a picture of the actuator in it's proper position. It can fall into the slot so that the cable end is nearly touching it, as Peter said. It's the #1 cause of what you describe, and it's a snap to fix. Picture is L.A.B's
Dead link deleted.

thecopperchick said:

hey all. i have a 71 with a 75 850E motor. the clutch is crazy hard for me to pull in. i know that they can be stiff, but i cannot even pull it in with one hand ( & i cut metal for a living & am not the weakest girl around). any suggestions?
thanks a bunch.

Click to expand...

If you search there are several good approaches to the clutch. There especially has been written much about cable routing and clutch stack height.

As others have mentioned, first make sure the operating lever inside the gearbox inner cover hasn't slipped down out of position, cable routing is important, and a nylon or teflon lined cable can also help to reduce the amount of force needed to operate the clutch.

Setting the stack height correctly can make a difference, if it's set correctly, as you pull in the clutch lever, it should acually begin to feel lighter as the lever comes back to the bar? If you have to increase the force on the lever to pull it in, then the stack height is probably not at its optimum setting.

http://atlanticgreen.com/ndnsclutch.htm
http://www.oldbritts.com/ob_clutch_info.html

When my clutch cable broke I replaced it with a Venhill teflon cable. What a difference! Now I have a very easy pull clutch. I've never checked stack height, but it too, is very important. Correct stack height with a teflon cable will probably get you a one finger clutch.

Correct me if I'm wrong, but you can put an extra plain clutch plate in the clutch at the back to bring the stack up & make it easier to use.
Clutch cable must have no tight bends, if it is tied to the frame, take the ties off.
My own clutch is harder to pull in than one of those springy hand excersize things, the ones that cool dudes use.
I may try an extra plate one day.

Flo said:

Correct me if I'm wrong, but you can put an extra plain clutch plate in the clutch at the back to bring the stack up & make it easier to use.

Click to expand...

It's not just adding a plate but making sure the stack is the correct height.