- Joined
- Sep 26, 2007
- Messages
- 292

I posted a question about 3 or 4 weeks ago when I suddenly started to have intermittent shifting issues (Mark 3 with 17K miles).
The bike would occasionally slip out of first gear as I revved away from a stop, and it would occasionally refuse to go from 3rd to 4th. (it may have been stubborn from 2nd to 3rd as well, but I particularly remember 3rd to 4th).
And the shifting just didn't seem to be smooth either.
Then the clutch cable broke.
I replaced the cable but realized the clutch feel was way off. It is a very hard pull, and it feels like the plates are fighting me. I parked beside another Mark 3 a few days ago to compare clutch pulls. The other one was smooth s butter and I could feel the clutch lifting. Mine is just not right.
I have been scratching my head to figure out what is wrong and can't seem to get to the bottom of this.
Words of wisdom would be greatly appreciated .....
So far:
- checked new cable - it's fine. I even swapped a couple of others in and out - same. It is routed nicely, no binding in the cable.
- the clutch actuator plate in the gearbox moves cleanly on its ball and is i perfect condition. It is lined up perfectly with the cable's line of entry into the gearbox cover.
- the clutch pushrod is straight and right on spec for length. It moves cleanly through its channel when the clutch adjusting screw is removed and the clutch lever is pulled. I can push the point of a philips screwdriver against the rod and work it back and forth via the lever. Nice and smooth.
- the clutch plates are all nice and kosher. No gouges or marks on inner or outer teeth.
- removed the primary chain, and engaged the clutch without the chain in place. it still feels like crap, no difference from when the chain is on - so that rules out possible sprocket alignment as an issue.
- I have poked around at this problem for days, and took it to a shop which regularly works on Commandos. They couldn't figure it out either.
Now, I guess I would be ok with a tough-guy clutch pull, which would give me a strong left wrist and I'd have to replace cables regularly, but he shifting issue is really a pain in the ass.
Any suggestions what else to look for? It's as if the clutch basket itself is warped or something, preventing the plates from lifting when the pressure plate is on. But I have pulled the plates out 3 times now - they all slide in and out of the basked nicely.
Help..............
Keith Kelly
PS - Barnett clutch plates on the bike, put on about a year and a half ago. But this problem just came up recently.
The bike would occasionally slip out of first gear as I revved away from a stop, and it would occasionally refuse to go from 3rd to 4th. (it may have been stubborn from 2nd to 3rd as well, but I particularly remember 3rd to 4th).
And the shifting just didn't seem to be smooth either.
Then the clutch cable broke.
I replaced the cable but realized the clutch feel was way off. It is a very hard pull, and it feels like the plates are fighting me. I parked beside another Mark 3 a few days ago to compare clutch pulls. The other one was smooth s butter and I could feel the clutch lifting. Mine is just not right.
I have been scratching my head to figure out what is wrong and can't seem to get to the bottom of this.
Words of wisdom would be greatly appreciated .....
So far:
- checked new cable - it's fine. I even swapped a couple of others in and out - same. It is routed nicely, no binding in the cable.
- the clutch actuator plate in the gearbox moves cleanly on its ball and is i perfect condition. It is lined up perfectly with the cable's line of entry into the gearbox cover.
- the clutch pushrod is straight and right on spec for length. It moves cleanly through its channel when the clutch adjusting screw is removed and the clutch lever is pulled. I can push the point of a philips screwdriver against the rod and work it back and forth via the lever. Nice and smooth.
- the clutch plates are all nice and kosher. No gouges or marks on inner or outer teeth.
- removed the primary chain, and engaged the clutch without the chain in place. it still feels like crap, no difference from when the chain is on - so that rules out possible sprocket alignment as an issue.
- I have poked around at this problem for days, and took it to a shop which regularly works on Commandos. They couldn't figure it out either.
Now, I guess I would be ok with a tough-guy clutch pull, which would give me a strong left wrist and I'd have to replace cables regularly, but he shifting issue is really a pain in the ass.
Any suggestions what else to look for? It's as if the clutch basket itself is warped or something, preventing the plates from lifting when the pressure plate is on. But I have pulled the plates out 3 times now - they all slide in and out of the basked nicely.
Help..............
Keith Kelly
PS - Barnett clutch plates on the bike, put on about a year and a half ago. But this problem just came up recently.