Clutch lever sticking V7 850

[Jonny_D]

Hi All.

First post here after searching the forums for an answer!

Just got my 2021 V7 850 back after a new exhaust system being fitted. First ride this morning and several times the clutch leaver would stick at fully open after I had pulled it, until I manually forced it back closed. Only happened if I pulled the clutch fully in, happened maybe 7 times on an hour ride.

Is this just the bike not being ridden for a while and/or need for lube on the clutch cable etc? Or something else?

I'm a bit of a novice with maintenance so any advice much appreciated.

Thanks,

[faffi]

I would check how the clutch cable is routed first. Could the outer shield have melted on the exhaust somewhere, or did the shop accidentally route it wrongly?

Also, how is it to pull? Same as before, or does it take more effort? If there is enough friction to prevent the clutch springs from pulling the cable back, you should feel it at the lever.

[Dirk_S]

Could be one of a couple things (my thoughts only, not a mechanic):

• Your cable could be catching somewhere along its route down to the clutch arm located behind the transmission. Perhaps the cable was extremely corroded (unlikely), or maybe it became trapped during removal and reinstallation of the tank. Check your cable routing;

• Maybe the barrel on either cable end is catching and not properly rotating. This is the only part of the cable you should lubricate, with grease, unless the barrel has the plastic barrel sheath, which typically provides smooth rotation; check the cable ends that they’re not beginning to fray or bend the cable;

• The clutch pushrod in the back of the motor might be sticking in the shaft. You could check this by waiting for it to stick again (testing with the bike parked), and checking the tension of the cable down at the lower end where it connects to that clutch arm. If the cable isn’t taut, then the pushrod bearing needs to be replaced.

PS - Welcome to the forum!

[Jonny_D]

Thanks both for your advice.

Clutch pulled the same as before and feels fine other than getting stuck about 1 in 3 times at full pull.

When I'm finished at work I'll check all the routing, the barrels at either end and if these seem fine, the pushrod.

Thanks again,

[pehayes]

I had an SPII which allowed a new cable to rub against the exhaust header.  The outer waterproof coating melted allowing the internal steel coil to now contact the header.  The heat transferred along the internal steel coil which subsequently melted the plastic internal friction liner into a puddle.

Stopped and parked overnight.

Next morning the clutch handle wouldn't move at all.  The friction liner had meted into the working cable core strands and then cooled to re-solidify.   Result was rock solid.  Only solution was another new cable.  Bad juju can happen if you're not careful with cable routing.  Also think about wind resistance at highway speed and see if that moves the cable away from stopped position.

Patrick Hayes
Fremont CA

[Moparnut72]

Since the exhaust was the last thing worked on odd are that it has something to do with your problem.
kk