Clutch Push Lever/Actuator

I went riding this weekend and had a problem with my clutch lever adjustment. Maybe the experts here can help.

I put in new clutch plates last week and went out for a ride. I use the same process/procedure that I have used the last two times I replaced the clutch on this bike. It ran good up and down the block, so I took it out to the mountains for a ride.

I started the day out just fine. I was riding, climbing hills and clutching my way up and over rocky terrain.

About 30 miles into it, my bike was boiling over big time and my clutch was slipping really bad to the point that I got stuck on a hill. I coasted back down and started trying to figure out why the lever was so damn stiff and I couldn't get any play in to it.

What I ultimately found was that the clutch push lever was rotated outward from its normal position by almost 45 degrees. It was actually wedged up against the case saver. So I took off the lever and the case saver and the clutch push lever actually rotated over the chain. Because it was naturally so far out, I couldn't adjust the lever and had to ride very, very slowly back to my truck, clutch slipping and all.

On the push lever/actuator, what controls the position that it is in? Is there some sort of gear or spline on the top of it where I can take it out and reposition it?

How in the heck would it move anyways? Is this indicative of more damage.

Is it possible that something is wrong with the clutch plates I installed. I used OEM.

I looked in my service manual and I cannot see what holds that push lever in place.

What part of it actually moves the push rod. I cannot see that clearly in my diagram.

I guess I can take out the pushrod and remove the arm. I shouldn't have to remove the clutch basket to do that, right?

I am trying to understand what the heck went wrong here. I was about 15 miles from my truck at the time it screwed up on me and want to make sure that I fix it properly so I don't get stranded on my next ride.

Thanks for any assistance.

Create an account or sign in to comment

You need to be a member in order to leave a comment

Create an account

Sign up for a new account in our community. It's easy!

Register a new account

Sign in

Already have an account? Sign in here.

Sign In Now