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 Post subject: DRZ400 clutch very stiff advice please
PostPosted: Wed Dec 09, 2015 10:33 am 
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80 cc

Joined: Fri Jan 07, 2011 9:36 am
Posts: 36
Hi all,

i replaced my clutch cable in summer of this year, have been out about once a month since, but last 3 times the clutch has been very stiff.
it has warmed up a little during the day, or i have got use to it.

but this morning, i went to use and was as stiff as normal, so i tried to action a few times to loosen, which it did really well, by BREAKING.
the nipple just pulled off the end.

I am wondering if anyone has seen this before and if anyone has any advice on what it could be?
or what i need to check?


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 Post subject: Re: DRZ400 clutch very stiff advice please
PostPosted: Wed Dec 09, 2015 10:34 am 
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Moderator
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Joined: Sat Apr 04, 2009 12:39 am
Posts: 1713
Location: Kent
If the cable is ok then..ie you said its almost new...

You have could either have, a bent acuator shaft or a bent push rod.

Clutch pack issues are a slipping clutch, a notchy clutch or a grabby one


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 Post subject: Re: DRZ400 clutch very stiff advice please
PostPosted: Wed Dec 09, 2015 11:19 am 
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650 cc Monster
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Joined: Fri Dec 07, 2012 2:22 pm
Posts: 2439
Location: Romiley
Greetings,

Not sure if your clutch will be the same as that fitted to the Bata Alp 4.0 but I think that it should be. Anyway they are all very similar so take a look at a powerpoint type presentation that I put up on the internet;https://drive.google.com/file/d/0B1BIdt6JX4ukOFhXUmxLNEtSTXM/view?usp=sharing

Might I suggest that you check;

have you got the correct cable?
the movement of the inner clutch cable through its outer sheath when not fitted to the bike
the angle of the clutch perch to the cable entry
the shape and operation of the lever
the route of the cable
the angle of the at rest clutch release arm on top of the casing
the movement of the clutch release arm, held by a pair of grips, with no cable fitted
the clutch internals

Perhaps have a local member take a look with you, you do not say where you live but check out your local Group.

Hope these ideas help, please let us know what you find and how you fixed the problem to build up our knowledge base.

TTFN

Hugh.

Ps just thought of a really odd fault but which 'might' just be relevant, is there a really good earth connection between your engine/frame/battery as I have known control cables 'heat' up and seize when the starter is operated :!:

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Please note that I am not a National TRF Officer, any views expressed are my own and may not be in accordance with any official policy.


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 Post subject: Re: DRZ400 clutch very stiff advice please
PostPosted: Wed Dec 09, 2015 5:03 pm 
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650 cc Monster

Joined: Fri Apr 03, 2009 3:08 pm
Posts: 4440
Likely to be a build-up of dirt in the nipple recess on the handlebar lever.

This needs to be kept clean and oily as the nipple must be able to turn in the lever...there's a sleeve on the nipple to help with this on the genuine cables.


There are some shocking quality cables around...get either genuine Suzuki or Venhill.

Cheap rubbish is just that ...thanks be to China


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 Post subject: Re: DRZ400 clutch very stiff advice please
PostPosted: Wed Dec 09, 2015 6:48 pm 
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125cc

Joined: Mon Aug 22, 2011 12:19 pm
Posts: 139
Richard Simpson wrote:
Likely to be a build-up of dirt in the nipple recess on the handlebar lever.

This needs to be kept clean and oily as the nipple must be able to turn in the lever...there's a sleeve on the nipple to help with this on the genuine cables.


There are some shocking quality cables around...get either genuine Suzuki or Venhill.

Cheap rubbish is just that ...thanks be to China



I 2nd this. I bought a cheap cable for my DRZ, it was stiff and broke in 6 months. Defiantly get a genuine cable and keep everything clean and lubed.


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 Post subject: Re: DRZ400 clutch very stiff advice please
PostPosted: Thu Dec 10, 2015 8:06 pm 
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80 cc

Joined: Thu Mar 11, 2010 12:03 am
Posts: 98
+1 on buying a quality cable. Make sure it's routed properly- often people remove the old one and route the new one differently. It must be routed the same as when the bike was new.


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 Post subject: Re: DRZ400 clutch very stiff advice please
PostPosted: Wed Dec 16, 2015 10:33 am 
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650 cc Monster
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Joined: Fri Dec 07, 2012 2:22 pm
Posts: 2439
Location: Romiley
Greetings,

Wondering, have you sorted the problem with your clutch cable, if so what caused the problem?

TTFN

Hugh.

_________________
Please note that I am not a National TRF Officer, any views expressed are my own and may not be in accordance with any official policy.


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