Transmission questions

kontraband · Full Member Joined: Oct 29, 2008 Posts: 36

Hello, I'm hoping you can help me out:

- the clutch handle is extremely stiff. How can I fix that?

- the bike jumps forward when switching from neutral to first. Is this normal?

Bike is an 83 Heritage Special.

Thank you.

XSDAD · Full Member Joined: Sep 03, 2008 Posts: 176

On the left hand case, there's a circular hole cover that you can pop off, the clutch is adjusted from there. You'll need a wrench to hold the nut while you use a phillips screwdriver to turn the screw in all the way and then back it up about 1/4 of a turn. I had the same problem with my '83.

kontraband · Full Member Joined: Oct 29, 2008 Posts: 36

XSDAD wrote:

On the left hand case, there's a circular hole cover that you can pop off, the clutch is adjusted from there. You'll need a wrench to hold the nut while you use a phillips screwdriver to turn the screw in all the way and then back it up about 1/4 of a turn. I had the same problem with my '83.

Sounds straightforward, I'll try it when I get back tonight.

XSDAD · Full Member Joined: Sep 03, 2008 Posts: 176

check out this site, good info:
650wiki.org/index.php/Main_Page

Retiredgentleman · Posted: November 17, 2008, 5:57 pm Post subject: Re: Transmission questions

Several things to check on:
Remove the left side engine cover. Disconnect the clutch cable. Remove the clutch worm gear mechanism, clean it, look for any cracks or damage in the nylon screw. If no damage, re-grease it with lots of grease.
Check that the routing of the clutch cable has no sharp bends. Does the cable move freely in the sheath? Lubricate the cable.............I have found that a lubricant with graphite in it works well, but others just use motor oil.
With the worm gear and side cover re-installed, adjust the clutch at the side cover. Adjust the clutch cable at the lever so that there is free play; unlock the nut, and turn the screw in until it bottoms then back out 1/8 turn, re-lock with the nut.. Now adjust at the lever so that there is a small amount of free play.
This may help, if not others will have some ideas.

kontraband · Full Member Joined: Oct 29, 2008 Posts: 36

Retiredgentleman wrote:

Several things to check on:
Remove the left side engine cover. Disconnect the clutch cable. Remove the clutch worm gear mechanism, clean it, look for any cracks or damage in the nylon screw. If no damage, re-grease it with lots of grease.
Check that the routing of the clutch cable has no sharp bends. Does the cable move freely in the sheath? Lubricate the cable.............I have found that a lubricant with graphite in it works well, but others just use motor oil.
With the worm gear and side cover re-installed, adjust the clutch at the side cover. Adjust the clutch cable at the lever so that there is free play; unlock the nut, and turn the screw in until it bottoms then back out 1/8 turn, re-lock with the nut.. Now adjust at the lever so that there is a small amount of free play.
This may help, if not others will have some ideas.

Thank you for the information.

weekendrider · Posted: November 17, 2008, 7:47 pm Post subject: Re: Transmission questions

Pay attention to position of the arm on the push rod cam when you take it apart. It will make it easier when you go back togather.

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