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Discussion Starter #1
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
 

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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 )

..Tom
 

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Pull the sprocket cover and look inside. Any debris could cause the lever mechanism to jam.
 

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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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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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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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Discussion Starter #8
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
 

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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.
 

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It is funny how a little more information like heated grips and muffs changes everything.
 

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The old heated grips.
I was following my mates down the Hume Hwy.
All acceleration just not happening, could not work it out.
Yep throttle twisted and the heated grip was hitting.
Every so often I had to back off and twist it back.
Still have not fixed it, summer time here.
On the list.


Harry
 

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I used Bison spray adhesive to glue my heated grips. I sprayed the glue and immediately put the grips on the handlebars. Didn't work: even the grip on the throttle sleeve rotated. Took 'em off and without respraying let them air-dry a bit. Put them on when the glue became tacky. Never a problem since.
 

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Since you were concerned about a frayed clutch cable, maybe now is the time to get a spare and throw it in your side case or strap it on somewhere. Having had two cables break in the past (on other bikes) it is comforting to know that now I won't have to try to ride home without a working clutch release. Pretty cheap insurance.
 

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Only had one clutch cable give out but it is a real bother riding home without the clutch working at it's best.
It tests your hand and foot skills.
 
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