Clutch cable / sprocket cover install

[FordFoxGT]

OK guys. I did a search and didn't find anything like my problem. If I missed it I apologize.

I had the clutch cable and sprocket cover off the bike completely. When I put them back on I can't get my clutch to engage at all. I can put the bike in first (bike running) and let the clutch lever out all the way and I go no where. In any gear I can roll the bike back and forth like it's in neutral or the clutch is disengaged. Now with the cover off I can put the bike in gear and it won't roll, like the clutch is engaged. Like it should be.

So I know that it's the cover / cable that's causing my problem. Is there anything that I should know about putting them back on? I'm not seeing anything obvious and it worked before I took it off. Could it be the routing of the cable? If so pictures of proper routing would be greatly appreciated. Thanks guys.


Smitty

[FordFoxGT]

It's not an issue of shifting the bike. It'll go into every gear just fine with or without the bike running, clutch in or out. I did a frame and fork swap and I went to take it on a test ride yesterday and nothing happened when I let go of the clutch. I had the cable and cover completely off the bike. I shot some parts cleaner on the release mechanism on the cover. Everything seems to work as it's supposed to. I've had the adjuster on the bars full out and full in and every spot in between. I'm not near my bike so I can't post pictures right now.

I was thinking that maybe not having that gasket on there may be allowing the cover to go in to far towards the case or that the release mechanism may have self adjusted to far out. I did squeeze the clutch a few times to make sure that every thing worked before I initially put it back on. It has to be some thing that I'm doing / not doing at the cover.

[95FZR600]

You need to adjust from the bottom and the top. Take the little black plug out from the cover and adjust that as well as the lever.

[FordFoxGT]

AH HA!!! I'll be trying that out as soon as I get home. I wondered about that little plug. Thanks guys.


Smitty

[tkclow]

According to Haynes manual, remove plug, loosen lock nut, and screw in the phillips adjuster screw just until it bottoms, then back it off 1/4 turn, tighten lock nut. Then adjust cable at lever. I ended up having to adjust the screw out about 1/2-3/4 turn before clutch engaged and the bike moved. Hopefully that helps you out a little to start with.

[FordFoxGT]

Adjusting that screw was exactly what I needed to do. I just "rode" her up and down my back ally a few times. Now I just need to get the carbs situated and I might actually be able to ride instead of stumbling, bogging and coasting.

Thanks again guys.


Smitty