Has anyone experienced clutch cable issues on longer rides?
It seems that when the bike, and of course the clutch cable, get really heated up, I have trouble getting into first gear at a dead stop.
When this happens, I have noticed that there is much more free play in my clutch lever, and if I readjust/tighten the cable, the first gear issue goes away.

The problem is that when the bike cools down, there is absolutely no play in the clutch lever and I am afraid if too tight, I won't get full engagement under load.

This only happens on longer rides. The cable is a Motion Pro HD cable for a KLX300 (as it is couple inches longer than the 250 cable) and is probably 2 years and 5,000 miles old.

Am I overlooking some other obvious cause? The actual clutch plates can't shrink when hot? Seems the steels would expand it anything?

TIA for any input or common experiences,

TC

 

That is the craziest thing I heard today.
I don't think the cable is getting hot. What kind of trouble you having getting it into first?
I think your clutch is getting hot, expanding and when that happens your lever has more play due to the plates sitting higher. When it get hot, your clutch cannot be fully disengaged cause your clutch plates are HOT!
You really only need your clutch for first, give it a break!

 

Yeah, 30 plus years working in the motorcycle industry, I have never heard of this....LOL Yes, cables have been known to stretch, but after years and years of heavy use, but not that Motion Pro HD cable, thats for sure.

 

Haha, wasn't going for the crazy award but was just trying to figure this out - that's why I asked.
The issue is that it doesn't want to go into first gear from neutral at a dead stop. it seems to want to rebound back into neutral. It goes into first just fine when rolling to a stop or if I shut off the engine. As mentioned, when it does this the clutch cable has more slack than normal and if tightened up, it shifts into first just fine so I figured it was a clutch issue.
I have never experienced this until this this summer, and on longer rides like the WABDR, but I am now recalling that I replaced the clutch over the past winter, so this is my first season on this clutch.
Is the EBC Dirt Racer a decent clutch kit. It didn't cost much but I thought EBC had a good reputation.
Thanks again,
TC

 

I would check the route of the cable while activating it, sometimes the cable moves everytime the lever is pulled and causes a bunch of slack. You don't want that.
I think your cable is fraying at the lever probably and needs to be replaced. Or your clutch plates/activation mechanism are bad.

 

Thanks for the pointers. I lubed up everything today and changed the oil... everything looked oK...will see how it behaves!
TC

 

I decided it was time to replace mine, 07---9 years old and no signs of wear but for $16 and some peace of mind I changed out with OEM cable. The new one felt much smoother than the old, a little peace of mind and an easy change.