Clutch take up has changed

[Expat]

Have an odd thing going on with the clutch on my ‘60 G3 that only really came about after a long period of disuse and is becoming more noticeable.
Most noticeable when pulling away from a standstill, the bite point is now very close to the end of the handlebar lever fully relaxed position, ie fingers off the lever. Have checked the clutch rod setting which seemed fine as does the free play at the cable entry point on the g box cover. Clutch doesn’t seem to be slipping or dragging at all but I’m a bit concerned that there’s a problem around the corner if the issue isn’t investigated. The amount of cable slack at the h bar lever is normal but to me, it’s acting like there isn’t any.

Any ideas chaps?

[Expat]

No takers, or am missing something blindingly obvious like there’s nothing wrong with it?

[clive]

The bite point is normally controlled by the clutch rod setting and free play in the cable, i would be inclined to check the rod adjustment again. Possible cause of problems, one spring uunwinding causing the bite point to be later. If you keep needing to adjust the cable free play then its possible the wire is gradually pulling out of the handlebar nipple, not unusual with pattern replacements where the wire is directly iinto the nipple rather than a separate slotted nipple.

[Ianwilko13]

Something is coming loose? First check the nipple and lever fulcrum at the handlebar end, next open the gearbox inspection cap and check the nipple, fulcrum and lever inside, if these all seem sound then the chain case will need to be split, operate the clutch and look at the clutch Sprocket to see if it is being pushed out it may be the nut holding it on to the gearbox output shaft has worked loose, if your lucky it may be the pushrod adjustment screw loose, at least it isn't Sunday teatime in a layby in the rain, Good luck with your search, Ian.

[SPRIDDLER]

Normally it's the opposite, i.e. over time the bite point needs the h/bar lever to be pulled closer and closer to the h/bars.
As Ian mentioned, maybe the slack in the cable is allowing the lever end of the outer cable to relocate itself in the lever assembly, or the nipple at the clutch end is mis-locating due to the slack.
My only other thought is that the inner has a broken strand which is snagging or bunching up inside the outer, somehow creating a ratchet effect and a false setting when you adjust the cable/clutch (but I'm having difficulty visualising that scenario). It's worth checking by disconnecting the cable at both ends to check if the inner slides smoothly.

[Expat]

Thanks everyone for the helpful suggestions. I will check them all out on my return from holiday though I do suspect there’s something going on with the clutch itself so the chain case will have to be split, it’s weird that there’s no drag or slip happening.

Many a true word re layby and rain Ian.

[Expat]

Finally after a ton of distractions, got around to looking closer at the clutch. Have got as far as removing the pressure plate, adjustment screws were set equally, springs not broken and clutch center drum not loose or rocking which I would have would expect if the main shaft nut was loose. Would that be the case?
Haven’t stripped out the plates yet as I’m not sure what I’d be looking for at this stage. There doesn’t appear to be any notching of either drum.
The pushrod adjustment was about right and not loose so feeling a bit lost at the moment. Maybe I need to go back to the cable operation and look much closer?

[clive]

Different gearbox but i was having trouble with my clutch a while back and found the problem was at the other end. The nut holding the mainshaft had come loose. This would allow the shaft to move across changing the bite point and then floating back under drive? Worth a chdck but it means the outer case coming off. On my G11CS with the same gearbox the plates tend to hammer on take up. Mine has the plates with the external ears for the friction plates so this is obvious. If you have tbe other type of friction plate with the internal slots they could have damaged the plates they slide on. Difficult to see how that would cause later bite but i guess it could if they get caught up.

[Expat]

Thanks Clive, I will check out the nut at the other end when next I can spend some time in the shed. Had planned to replace gear change oil seal, so cover has to come off anyway.
Weather has been extremely hot and humid here for a while and the tin shed gets like an oven inside. Even a/c and a fan struggles.

[limeyrob]

Does this have the ball/cup mechanism to convert the cable pull to push on the rod? If so I would take that apart and clean and grease it to make sure the balls all roll equally and it spring back freely.