F7 Clutch won't release completly?

Oldrider

Hi everyone, new here, just found this site!
Need help with my 1971 F7 clutch. I was given this bike by it's original owner and my best friend. 10k miles on it. The problem is, the clutch will not completely release. I have taken all the adjustment out at the lever, the in-line cable adjuster and at the screw mechanism on the left case. It's almost like there is just not enough travel in the lever. I can start the bike, but when I go to put in gear, it wants to jump forward. I can ride it around and it will shift while its moving but when you come to a stop, it's impossible to get back into neutral unless you stop the motor.
I have taken the left case off and cleaned/greased the "screw" and it all looks fine there. My friend said the problem started when the clutch cable broke one day. When he couldn't find a new cable, he went to the local M/C salvage yard. They sold him the cable and gave him the complete left cover with the release mechanism, which he went home and installed. The old cover was thrown away. He thinks he remembers changing both handle bar levers at the same time, (clutch and brake), with "aftermarket" assemblies.
So, any ideas?? I'm thinking the lever just doesn't have enough travel. Did the original levers have different geometry that allowed more pull length? Any and all help is greatly appreciated. Thanks!!!!

Steven

650hardtail · Posted: Sun Jan 03, 2010 10:54 am Post subject:

could be the lever..but how long has the bike sat ???
manytimes its just the clutch plates have become stuck after years of storage..

Oldrider · Posted: Sun Jan 03, 2010 11:56 am Post subject:

Yeah, I thought of that, but the bike never sat too long. The PO's son would use it ever so often and the problem showed up at the cable/housing/lever replacement time. With that being said, maybe I just need to take the clutch apart and take a look. Thanks!!

Steve Searles · Posted: Mon Jan 18, 2010 12:35 pm Post subject: Clutch

Of course you need to take the clutch completely apart and check the steel and fiber plates and springs. Now here is the secret. I am 85% sure that the aluminum outer clutch basket has worn grooves in it from the tabs of the fiber plates and will not slide in or out properly. Happens all the time. New outer or file the basket smooth so no grooves are present until it does it again. You need to take the clutch apart.

Oldrider · Posted: Tue Jan 19, 2010 9:44 pm Post subject:

Thanks Steve, I think your right. I just need to find a few spare hours and tear it down.

H2Lou · Posted: Wed Jan 20, 2010 7:34 am Post subject:

some clutches have a 1/4" or 6mm ball bearing in them to reduce contact area...if this fell out when the side cover was taken off you won't be able to get the travel on your cable.

Lou

Steve Searles · Posted: Wed Jan 20, 2010 7:44 am Post subject: Jeans

Sounds like you have been around cycles a day or two Lou. I hate when that ball falls out and rolls around on the floor. I wear holes in the knees of my jeans looking for that stupid thing. Hey, I think I should buy stock in Levi !! Laughing

Oldrider · Posted: Sun Jan 24, 2010 7:53 am Post subject:

Thanks Lou. The missing ball theory was brought up by another friend a while back. I did find one the right size and installed it. No luck. All that did is change the overall length of the "pushrod" to the length of the "pushrod and ball". I just had to back out the adjuster to compensate for the additional length but it didn't effect the clutch release problem. BTW, I can run the adjuster in past the point of no free play and the clutch does release completely, but if you try to ride the bike, it then slips. This is why I'm thinking it just does not have enough travel. So at this point, I think I just need to disassemble the clutch and see what I can see. Thanks again for the advise and I will let you know what I find when I tear it down. Just need a little time that is not available right now.

Steven

sr71cbx · Posted: Sun Jan 24, 2010 10:23 am Post subject:

Steel clutch plates are likely warped. My old F7 I had a few years back did this, so had new plates on hand and cured the problem, and put some gorilla springs in it that I matched up off another bike.
Those bikes are indestructible.

Oldrider · Posted: Sun Jan 24, 2010 5:58 pm Post subject:

Ah Hah, now that is a theory that makes a lot of sense. And if so, it would explain all the symptoms. Maybe next weekend the clutch comes apart. Good place to by parts?? I am sure I'll need a new gasket, frictions discs, steel plates?, and maybe springs. Thanks. Shocked

bobbyjim · Posted: Wed Mar 31, 2010 5:47 am Post subject:

If you find out that you need a clutch cable then I have a brand new NOS Kawasaki cable that I will part with. It's an original Kawasaki F7 cable if needed.