Now my bike drags when it's in gear. I realize that some dragging is normal when the fibers are new, but how much is too much?? It seems like the push lever arm is too far forward before it meets resistance from the clutch springs.
The first picture is how far forward I can push the lever without any pressure:
This is how far forward it is when I adjust the free-play out of the cable:
And this is with the clutch lever pulled in:
As you can see in the last one, it maxes out. It starts to pull the knob on the end of the cable, into the cable housing. That doesn't seem right. Also, I had to use a spacer to get the cable tight enough to remove the freeplay. I thought the cable had stretched, but now I'm thinking otherwise given the other symptoms...
I've taken the clutch apart many times now to check it. I've removed and inspected the "push rod 2" and "push lever shaft" (these are the names in the manual). No signs of wear or bending as far as I can tell, but maybe it's just not visible?
EDIT: Push rod 2 is #11, and Push lever shaft is #19. If either of these were bent resulting in too much play, could I run an appropriately sized washer on top of #8 as a temporary fix? I've taken both out to look at them and neither look worn, but I can't figure out what else would be the problem.
The bike is rideable as-is, but I can't get into neutral while it's running. The clutch drags bad enough that the bike will drive forward when I give it gas in-gear with the clutch pulled in. However, it does not stall if I come to a stop with the clutch in.
Edited by cereal killer, May 27, 2012 - 04:01 PM.