thought my Clutch cable broke

but it did not and I drove home in 1st gear. I hade to really ram it in first to get it in there.
The Clutch handle just moves freely like it is broken but it is not. Clutch springs?

TIA

Clay

Take a look where the clutch cable is attached to the clutch arm(?). I didn't think mine was broken either, but the outside of the cable had frayed and it was just hanging on by the inside wire. It was basically acting like Chinese finger cuffs, if that makes sense.

If that's not it, then take your headset apart and see if the end of the cable is still in the handle. (or I think you can just see if it is when you squeeze the handle in).

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Owsley9 wrote:

Take a look where the clutch cable is attached to the clutch arm(?). I didn't think mine was broken either, but the outside of the cable had frayed and it was just hanging on by the inside wire. It was basically acting like Chinese finger cuffs, if that makes sense.

If that's not it, then take your headset apart and see if the end of the cable is still in the handle. (or I think you can just see if it is when you squeeze the handle in).

The cable is completely intact. My vespa had the same problem (hanging on with one little wire) I think this is going to involve me getting at the clutch.

TIA

Clay

could also be that the cinch bolt slipped on the back of the cable. if the cable is attached correctly at the top and bottom you wouldnt have the play in the lever regardless of the condition of the insides of the clutch. the cable and lever would still be tight

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	Quote:
	The Clutch handle just moves freely like it is broken but it is not. Clutch springs?

Do you mean the clutch lever or the handle (twist-to-shift)?

If the former, your clutch cable needs replaced, the cinch bolt has come loose, or it needs adjusted. FYI - You do not have to have an intact clutch cable to shift the vehicle into gear.

If the latter, check the gear selector cables. If the handle twists with no resistance and isn't changing gears, then it's likely the selector cables.

It is doubtful that the springs in your clutch are having any problems.

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matty_x wrote:

	Quote:
	The Clutch handle just moves freely like it is broken but it is not. Clutch springs?

Do you mean the clutch lever or the handle (twist-to-shift)?

If the former, your clutch cable needs replaced, the cinch bolt has come loose, or it needs adjusted. FYI - You do not have to have an intact clutch cable to shift the vehicle into gear.

If the latter, check the gear selector cables. If the handle twists with no resistance and isn't changing gears, then it's likely the selector cables.

It is doubtful that the springs in your clutch are having any problems.

I had a hard time getting it into first to drive it home. then once stopped another hard time getting it into neutral. I thought it could be the pinch bolt slipping but it was tight and I can move the pinch bolt all the way up the cable till it stops and my clutch lever will not budge when I pull it. I was forcing the scooter into first and driving in circles till the light went green. because I didn't want to stop. It is hard to push start a machine when stuck in gear. I can assure you the cable is all there and in one piece the shift cables are fine too.

TIA

Clay

	Quote:
	I can move the pinch bolt all the way up the cable till it stops and my clutch lever will not budge when I pull it

Can you explain this a little more?

What will not budge when you pull it, the clutch lever, or the pinch bolt at the clutch actuator arm on the motor? My understanding is that the pinch bolt is not moving, e.g., the actuator arm is not moving back and forth when you engage the clutch lever.

Let's pretend the clutch lever will not budge - you try to pull it but you can't. In that case, I would try these two things: First, make sure that the actuator arm can move. Get a good sized pair of pliers, grip the actuator arm, and push it towards the front of the bike good and hard. It will resist. If you've got movement, then you can rule that out as a possible cause. Second, disconnect the pinch bolt and disconnect the clutch lever. See if you can pull the cable back and forth. If you've got lots of resistance, then you may have a gummed up cable outer and need to replace the cable outer (and probably inner). This seems unlikely, though.

My sense is that this is an adjustment problem first and foremost. I wouldn't spend a lot of time trying to work out a larger problem like the above. When you adjust the pinch bolt, you have to pull the cable tight and then tighten the pinch bolt. This is after you've screwed in the adjustment screw all the way. A third hand tool is very helpful for this. Helps you cinch down the pinch bolt. Then you check where the clutch is engaging. If it's not engaging at all, you need to pull the cable tighter on the actuator arm via the pinch bolt. When you have it tight enough that it starts engaging, you can use the adjustment screw to fine tune the clutch in to where it feels comfortable.

The last thing that comes to mind is that the cable could have frayed in the headset. It's not impossible but less common than at the actuator arm. Check there too if all else fails.

Hope this helps.

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[quote="matty_x"]

	Quote:
	the actuator arm is not moving back and forth when you engage the clutch lever. .

Thank you for your reply. I can move the actuator arm on the motor freely, without hesitation, almost like it is just hanging there. So at one point I moved the pinch bolt on the cable so far the actuator arm on the motor was touching the cable guide. then the clutch lever had no slack and I could not take it in. once the pinch bolt is moved back where it was, the clutch lever just moves freely.

TIA

Clay

That tells me that the clutch cable is indeed intact. It is not broken.

My sense is that you need to play with the adjustment some. Instead of pushing the pinch bolt as far up as humanly possible, play with some intermediate areas on the cable. 3/4 of the way, 1/2 way, etc.

When I adjust my cable, I typically end up engaging the actuator arm a little bit before I cinch down the pinch bolt, FWIW.

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matty_x wrote:

That tells me that the clutch cable is indeed intact. It is not broken.

My sense is that you need to play with the adjustment some. Instead of pushing the pinch bolt as far up as humanly possible, play with some intermediate areas on the cable. 3/4 of the way, 1/2 way, etc.

When I adjust my cable, I typically end up engaging the actuator arm a little bit before I cinch down the pinch bolt, FWIW.

What bugs me is the actuator arm shows little if no resistance. I can move it with my two fingers without any effort.

Clay

	Quote:
	I can move it with my two fingers without any effort.

How much play is there? Mine moves I'm guessing about 1/4-1/2 inch with little effort. Then it gets difficult to move without extra tools.

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matty_x wrote:

	Quote:
	I can move it with my two fingers without any effort.

How much play is there? Mine moves I'm guessing about 1/4-1/2 inch with little effort. Then it gets difficult to move without extra tools.

I don't need those tools. that is what is bugging me. It just moves all the way both way's. That is why I thought I broke my cable.

Ideas?

Clay

Is this what happens when the nut on the clutch basket comes loose?

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FistsOfCurry: It ain't a rally, it's a PILGRIMAGE Mr. Green

Yeah, this is not a cable adjustment issue. It sounds like something internal. Your clutch isn't engaging. You can change gears and whatnot, but you cannot disengage the clutch.

Might be time to consider more drastic measures.

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Have scooter. Will travel.

Hey [heitwl], did you ever solve this? I have the exact same issue. I thought my clutch cable broke, but it's completely intact. My next step was going to be to adjust the pinch bolt, but when I move the clutch lever down at the engine it moves freely.

Was this a loose clutch basket?

Mine did the same thing last year,

the part that broke on mine was internal and behaved the exactly the same as you are describing.

On mine it was the piece that linked the actuator to the clutch assembly, At least that's what they told me ( I don't have a place that I can tear down a case right now.)

I wish i had something more encouraging to say .... Crying or Very sad

Have fun

Dirk

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