Clutch feels like pulling a Ton

[MNBikerPup]

Ok guys, I got a 81 KZ650 and squeezing my clutch damn near takes two hands just to squeeze. I have tried adjusting at the handle end, midline, and at the engine line. When I adjust at the engine it gets softer, but then it won't engage like it is supposed to. I did have the cover off for cleaning this last winter. Prior to this, the clutch felt like any other clutch. Any ideas? Am I missing a part? Any help at this point would be great. I need to ride. Thanks.

 

[famousseajay]

Have you tried lubing the cable? After sitting for a while the cable may have gotten a bit stiff/rusty. They make special cable lubing tools that attach to the end of the cable allowing you to force lube into them.

 

[Tim]

Check the worm-gear drive down on the engine (take the plate off again).

Make sure it's greased really really well with nice new grease, and make sure the cable is attached at the far end of the lever to maximize the leverage. Some levers have a couple of positions to mount the cable thingy to.

Also make sure that yes, the cable is well and properly lubed with cable lube, not WD40 etc. and that it is a nice smooth run between lever and engine - no sharp bends.

 

[MNBikerPup]

Ok, still having issues with my clutch. I have adjusted at the engine, mid cable and at handlebar. Either it won't engage meaning that when the motor is turned over in 1st with the clutch lever squeezed it wants to lurch ahead, or if adjusted where this doesn't happen, then the clutch won't engage at all. Do you think I need new clutch pads? And if so, how is this possible if I haven't ridden the bike in over a year, and prior to not riding the bike clutched just fine.

 

[grizwold]

Having this same problem with my CB500t. Pulling the clutch lever in doesn't disengage the clutch so when I put it in gear it wants to go. Bike has been sitting for around 2 years. I've read that after sitting for a while the clutch plates tend to stick together so they won't disengage. I'm hoping that's not the case but I may have to pull the clutch this weekend and see.

 

[hillsy]

Ok, still having issues with my clutch. I have adjusted at the engine, mid cable and at handlebar. Either it won't engage meaning that when the motor is turned over in 1st with the clutch lever squeezed it wants to lurch ahead, or if adjusted where this doesn't happen, then the clutch won't engage at all. Do you think I need new clutch pads? And if so, how is this possible if I haven't ridden the bike in over a year, and prior to not riding the bike clutched just fine.

Originally you said you removed the clutch actuator cover and the problems started after that. I'd say you have done something to the actuator when you re-installed it. Undo the sidecover and re-check the mounting of the clutch actuator.