Gday guys,

I've been doing some maintenance and repair on the moto in the USA after my trip north from Chile. My 2010 DR650 now has 47000 km on it and is doing pretty dandy I'd say.

The other day I was repairing a melted wiring loom and afterwards routed all the cables and tied them up again. I moved the bike and noticed the handlebars going tight on a left turn as the cables were too tight. I think this has caused a problem with my clutch dis/engaging.

So the bike starts fine in neutral gear. I can change it to 1st no worries with no clutch lever in, but it jumps/lurches. Also if I start it with the clutch lever in the bike will creep. As well as that its very difficult to move in 1st gear with the clutch lever in.

I've tried adjusting the cable at the lever and the other adjuster, as well as removing and relocating the clutch arm on the case. Could I have stretched the cable when turning my handlebars? Is there a simple solution to this I'm blindly missing?!

Did a little research and found an image on the clutch arm and ideas to render the problem, alas no luck. If I adjust as suggested in the picture and manuals, there is no clutch lever play. Should I replace the clutch cable? Could it be internal (plates, springs etc)?
http://i974.photobucket.com/albums/a...itmapImage.jpg

Thanks massively for your help in advance! Nearly ready to ride on up to Canada to work for the winter to fund the next stage of the adventure!

Cheers,
Rossy.

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'10 Suzuki DR650. 2011+ RTW trip. Currently in Canada. www.followtheakubra.com

Unless you massively yanked the handlebars against the pull of the tight clutch cable there is absolutely no chance of having damaged it due to ir being tight. Equally there is nil chance of damaging the clutch internals.

What you describe always exists to some extent because almost all bikes (inc DR) use a wet clutch where there is oil in the clutch. This means there is always oil between the clutch plates when you disengage the plates (pull lever in) and this oil still transmits a little torque. This effect is much more noticeable when the oil is cold and thick. So unless the jerkiness when you put it into first has suddenly got much worse (and remember it will be worse in cold weather) I wouldn't worry.

Readjust the clutch cable to standard with a small amount of free play at the lever (essential) and you should be fine. If in doubt find another experienced biker or a bike shop to give you an opinion.

Good luck.

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Martin

currently at home and saving for the next trip

http://awayonmybike.adventureriders.com.au

OK thanks mate! It has increased significantly, but I hadn't tried riding it yet to. I'll see how it goes on a ride to the shop. Thanks for the tips!

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'10 Suzuki DR650. 2011+ RTW trip. Currently in Canada. www.followtheakubra.com

I know you said you checked this but it does sound like a clutch cable adjustment issue.

As navalarchitect said there is always a bit of creep but when the bike is on the ground that should not be noticeable unless the cable is stuffed and "stretching"

Have you taken it to the shop yet ?