Clutch lever will not pull back to the grip - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
DL650A - 2012-2016 DL650A 2012-2016 (L2-L6)

 17Likes
Reply
 
LinkBack Thread Tools Display Modes
post #1 of 15 Old 11-27-2018, 03:21 PM Thread Starter
Stromthusiast!
 
Join Date: Apr 2015
Location: Portland, OR
Posts: 204
Clutch lever will not pull back to the grip

I did search on "clutch lever" and read a few pages but didn't have any luck.
On Sunday when I started my bike the clutch lever would not pull back to the grip and had almost a hard stop, 1/2" from the grip. It would pull in just enough to stop and be in gear. After riding a few miles and stopping and working with it the problem went away 100%. Monday all was good. This morning when I started the bike the problem was back so much so that I can bearly get into neutral when I come to a stop. One thought that occurred to me as I write this is that both nights before this I put the bike on its center stand and lubed the chain.

Please help, I'm hoping I can resolve this without going to the shop.
All debug ideas are welcome and appreciated

2012 DL650A with 26K miles, no recent maintenance other than chain lube.
Cheers,
Loren

2012 DL650A Adventure 26K miles
Rides2Work is offline  
Sponsored Links
Advertisement
 
post #2 of 15 Old 11-27-2018, 04:03 PM
Super Moderator
 
V-Tom's Avatar
 
Join Date: Jul 2006
Location: Port Perry, Ontario, Canada
Posts: 12,551
I haven't had my 2012 DL650 for a few years so this might not apply.

How is the other end of the clutch cable? Could it not be seated right? (Same could apply at the clutch lever now that I think of it )

..Tom
Rides2Work likes this.

2006 DL650: 202,000 km 125,500 miles, Sold
2012 DL650 139,500+ km, 86,700+ miles. Sold
2015 DL1000 New July 2015 193,000+ km, 120,000 miles.

This can help preventing from cars pulling out in front of you (SMIDSY)
SMIDSY detailed report.


V-Tom is offline  
post #3 of 15 Old 11-27-2018, 04:54 PM
Super Moderator
 
Join Date: Feb 2017
Location: St. Louis, Missouri
Posts: 1,668
Rides...disconnect both ends of the clutch cable and see if the cable will move freely from one stop to the other both directions.
Ive had a cable that frayed in the conduit and wouldnt allow full travel.
Big B and Rides2Work like this.

Last edited by MAZ4ME; 11-27-2018 at 08:42 PM.
MAZ4ME is offline  
 
post #4 of 15 Old 11-27-2018, 05:42 PM
$tromtrooper
 
nvr2old's Avatar
 
Join Date: Dec 2006
Location: Greenacres, Wa.
Posts: 2,364
Pull the sprocket cover and look inside. Any debris could cause the lever mechanism to jam.
Rides2Work likes this.

DL-1000 L8
DL-650 K5 red(122K)
09 DRZ400
The thrill of living should never be traded
for the safety of existence.
Member of the 100,000 mile club.
nvr2old is offline  
post #5 of 15 Old 11-27-2018, 08:39 PM
Stromthusiast!
 
blaustrom's Avatar
 
Join Date: Apr 2008
Location: north east, Buffalo NY area
Posts: 2,497
1+ on the previous 2 comments.

Whilst you are at it make sure the clutch lever pivot is well lubed as well as the cable nipple pivot that fits inside the lever.

If the clutch cable is fine and moves ok, don't lube the cable itself, it's Teflon coated and not supposed to be lubed.
Big B, Gert and eff like this.

.
Blau1 2004 DL650-sold
Blau2 2014 DL1000A
blaustrom is offline  
post #6 of 15 Old 11-27-2018, 09:24 PM
Super Moderator
 
Brockie's Avatar
 
Join Date: Jul 2013
Location: Gatton, Queensland, Australia
Posts: 4,449
Garage
All of the above!
Remove the countershaft cover and check for the free movement of the lever there. Then disconnect the cable at both ends and check for free movement, and check the clutch lever also for free play.

It sounds like some debris or something loose is causing intermittent loss of full movement.

2010 Weestrom; 2017 Kawasaki Versys-X300; 1988 Suzuki GSXR1100
Brockie is online now  
post #7 of 15 Old 11-27-2018, 09:46 PM
Stromthusiast!
 
Join Date: Mar 2011
Location: Pasadna area
Posts: 13,456
I had the hand grip rotate on my bars and cause a similar problem on my 04 Wee. Caused some crunchy shifting. When the grip rotated the lever hit it before the clutch was disengaged.
I used some industrial adhesive on the grip to keep it in place.
V-Tom likes this.
notacop is offline  
post #8 of 15 Old 11-27-2018, 11:45 PM Thread Starter
Stromthusiast!
 
Join Date: Apr 2015
Location: Portland, OR
Posts: 204
Problem solved.
Thanks all for your great ideas and troubleshooting methodologies.
Notacop nailed it but at the time I left work I was armed with just the first three posts.
- Removed the sprocket cover to see if there was an obstruction.
- Removed the cable bracket next to the sprocket to get free cable play and confirmed that the issue was upstream.
- Removed my handlebar muff, didn't see the problem
- Removed the handguard and then saw the problem.
I have Oxford heated grips and the cable bump had rotated back and caused the interference. Actually, this happened as I'm wrestling the bike off of the center stand. This summer I'll glue the grip on, the Oxford instructions advised only gluing the throttle grip.
Again thanks for the encouragement and guidance.
You are why this forum rocks.
Kind regards,
Loren
Big B, V-Tom, pvwheeler and 2 others like this.

2012 DL650A Adventure 26K miles
Rides2Work is offline  
post #9 of 15 Old 11-28-2018, 09:40 AM
Stromthusiast!
 
Join Date: Mar 2011
Location: Pasadna area
Posts: 13,456
Yah, I used a spot of industrial adhesive to keep the grips in place. Those wonderful but moveable Oxfords were being a problem.
It did not take a very large dab of the adhesive. I can easily break it loose in the future if I need to. I used Locktite construction adhesive.

Last edited by notacop; 11-29-2018 at 04:21 PM.
notacop is offline  
post #10 of 15 Old 11-28-2018, 01:03 PM
Stromthusiast!
 
Rolex's Avatar
 
Join Date: Feb 2013
Location: Sydney's East
Posts: 2,824
It is funny how a little more information like heated grips and muffs changes everything.
Big B and Brockie like this.

Some of the 19 rides in my shed
2014 V2, Snoopy
2009 Wee, Pumbaa the pig
WR450F, The Blue Postie Bike
YZ250N smoker with rego, Stinky.
Yamaha MT09 (FZ09), The Scud missile.
Club Lead not Club Med.
He with the most toys wins.
Out of my depth in a puddle.
Live life on the edge you will see more that way.
Ridding a motorcycle keeps things in balance.
At the end of each trail and at the end of each day history is made.
Rolex is offline  
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
excessive front brake lever travel: one solution dtalk Maintenance, Tech and Products. 54 06-26-2017 09:33 PM
Tough To Pull Clutch Lever albmw1100rtp DL1000 from 2002-2012 3 05-30-2017 02:13 PM
Replacement clutch lever with clutch safety switch TheCondor DL650 and DL650A - 2004 to 2011 8 05-14-2015 09:56 PM
Clutch lever pull (too light) tenny80 V-Strom Service and Maintenance Questions and Discussions 15 02-28-2015 08:43 PM
Clutch lever question 2kMarauder DL650 and DL650A - 2004 to 2011 12 09-19-2009 11:34 AM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome