Shit. That doesn't sound good. Ya the spring inside was stretched out quite a bit when I installed it. I'll take a pic when I get home and post it up.
I can't imagine Charlie's Place would sell me the wrong cable though. we'll see.
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Replacing Clutch Cable
After trying the full method, with the fat "adjuster" screw and all, I thought I was fucked. I called Charlie's again, thinking it HAD to be the cable, and he set me straight. He told me to check on the push rod. I pulled it out, inspected it, it looked perfect, and re-inserted it. After I re-assembled, everything worked great. The push-rod must've been moved out of its little spot and gotten stuck on the lip of the thing it fits into, which is why I was having such weird symptoms. Hopefully I didn't damage anything with all the messing around that took place after that happened.
Still one minor issue. The clutch cable pulls really tight. I can't route it under the tank, or else it pulls really really stiff. And still seems to pull kinda stiff when it's complete free, sticking out from the bike. Why is this going on? Is there anything I can do to fix it? Is it just because the outer housing of the cable is too long, therefore, it can't be cleanly routed without bending the outer housing, causing a kink? Seems weird, especially considering Charlie uses these cables for every bike, and I SAW some of those cables on bikes at his shop.
Come to think of it, the stiffness reminds me of the way it was when I first got the bike. I remember thinking the clutch was really stiff on this bike, then figuring I "got used to it," but really the cable frayed, reducing tension, and then I noticed it was three threads from snapping apart.
Anyone have similar issues? Should I try and fab up a weird solution by shortening the housing with a dremel or something? Tips please.
But for now, she runs again. Victory.
Still one minor issue. The clutch cable pulls really tight. I can't route it under the tank, or else it pulls really really stiff. And still seems to pull kinda stiff when it's complete free, sticking out from the bike. Why is this going on? Is there anything I can do to fix it? Is it just because the outer housing of the cable is too long, therefore, it can't be cleanly routed without bending the outer housing, causing a kink? Seems weird, especially considering Charlie uses these cables for every bike, and I SAW some of those cables on bikes at his shop.
Come to think of it, the stiffness reminds me of the way it was when I first got the bike. I remember thinking the clutch was really stiff on this bike, then figuring I "got used to it," but really the cable frayed, reducing tension, and then I noticed it was three threads from snapping apart.
Anyone have similar issues? Should I try and fab up a weird solution by shortening the housing with a dremel or something? Tips please.
But for now, she runs again. Victory.
Glad to hear your back on the road! Let's make sure we have it right though... The clutch cable should pull with no resistance if it's not hooked up to the actuator.
Routing - It should go from the lever perch, down between the speedo and handlebar to the right side of the frame. From there it should go above the forward tank mount and make a gentle bend down to the right case.
Inside the right case, the wire should make a slightly acute angle with the actuator arm. If all this is correct, the clutch should actuate smoothly with just a little more pull than a modern bike.
Aftermarket parts such as the cable itself, adjusters, clutch plates and springs, and incorrect routing can lead to the issues you're having.
Routing - It should go from the lever perch, down between the speedo and handlebar to the right side of the frame. From there it should go above the forward tank mount and make a gentle bend down to the right case.
Inside the right case, the wire should make a slightly acute angle with the actuator arm. If all this is correct, the clutch should actuate smoothly with just a little more pull than a modern bike.
Aftermarket parts such as the cable itself, adjusters, clutch plates and springs, and incorrect routing can lead to the issues you're having.
Went to Charlie's Place and felt some other cb77 clutch levers and they felt similar. Also asked Charlie who said CB77 levers are just kind of tight. He examined the tension of the clutch lever on my bike and said it was okay. He said with the aftermarket cables, some people leave them un-routed and use a zip tie to hold it closer to the frame so it's not protruding. Seems good enough to me!
Wanted to post a quick update. Clutch cable is pulling well. As I said it was a bit tight when I installed it, but then I went on a good ride Friday afternoon, maybe 20 miles, and after that it loosened up. Do the cables break in at all? Perhaps it was the housing loosening up as well. I checked the cable at the lever (where it frayed before) and it still looks really good.