Clutch lever will not pull back to the grip - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 15 Old 11-27-2018, 03:21 PM Thread Starter
Join Date: Apr 2015
Location: Portland, OR
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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.

2012 DL650A Adventure 26K miles
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post #2 of 15 Old 11-27-2018, 04:03 PM
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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 )

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post #3 of 15 Old 11-27-2018, 04:54 PM
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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.
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Last edited by MAZ4ME; 11-27-2018 at 08:42 PM.
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post #4 of 15 Old 11-27-2018, 05:42 PM
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Pull the sprocket cover and look inside. Any debris could cause the lever mechanism to jam.
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post #5 of 15 Old 11-27-2018, 08:39 PM
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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.
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post #6 of 15 Old 11-27-2018, 09:24 PM
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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.

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post #7 of 15 Old 11-27-2018, 09:46 PM
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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.
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post #8 of 15 Old 11-27-2018, 11:45 PM Thread Starter
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Location: Portland, OR
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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.
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Kind regards,
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post #9 of 15 Old 11-28-2018, 09:40 AM
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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.
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post #10 of 15 Old 11-28-2018, 01:03 PM
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It is funny how a little more information like heated grips and muffs changes everything.
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