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XV 920 Handlebar swap -> clutch issues

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XV 920 Handlebar swap -> clutch issues

PostAuthor: firstoffive » Wed Jan 29, 2020 7:49 pm

Hey all!

I recently replaced my 1982 XV 920's handlebars in favor of some 28 inch drag bars, and the swap went well, up until I tried to actually ride the bike. The clutch did not engage at first, but the bike would start without problems (not in Neutral). I moved the actual cable around and fiddled with it until I could get things to engage and the bike back into neutral.

Everything was working well until I changed the bars, and now nothing is working like it should.

Any help you can give me would be greatly appreciated!
1982 Yamaha Virago XV920 - Cafe racer mod in progress
- Handlebar mounts swapped for 1985 Virago XV1000 brackets
- Bars changed to 28 inch drag bars
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Re: XV 920 Handlebar swap -> clutch issues

PostAuthor: nanno » Thu Jan 30, 2020 1:28 am

... and your question is?
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Re: XV 920 Handlebar swap -> clutch issues

PostAuthor: Flyingdog » Thu Jan 30, 2020 5:20 am

:VTF:

Wow..something had to be touch..you would think. What..did you actually fiddle with, to get it back into neutral? Will the bike move while in any gear, but clutch level pulled in (clutch plates disengaged)? How's the lever feel? Is the friction point at bout the same as before you changed bars?..You might be just outta adjustment, cuz to the change'n angle of cable. Going by a manuals' procedures... I'd suggest do'n a full clutch adjustment from the push-rod/clutch plate/lever...to...the handle bar adjuster, to begin with. Then move on to other trouble shoot'n as the manual would suggest.
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Re: XV 920 Handlebar swap -> clutch issues

PostAuthor: Jake » Thu Jan 30, 2020 7:27 am

I deleted your duplicate post in Tech Help.

You only need to post one topic per issue/problem. Multiple threads on the same topic will not get you faster or better answers, most likely just duplicate answers. If different solutions should be offered, it's better to have them on one thread.

I also moved nanno’s post over to this thread.

One more thing,

:VTF:


Please add your location to your profile so no one has to ask in the future. With members all over the globe, some info is geographically specific.

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Re: XV 920 Handlebar swap -> clutch issues

PostAuthor: firstoffive » Fri Jan 31, 2020 11:00 am

nanno wrote:... and your question is?


So the question revolves around the fact that a) the clutch was engaged enough that the bike would start and run when it was not in Neutral, but not move when I rolled on the throttle, and b) when I fiddled with the clutch cable things started to work, KIND OF.

My main question is what should I do from this point? I am tempted to disconnect the clutch cable and get the bike up on the centerstand so I can shift through the gears and see how things go. I'm thinking there is tension on the cable, keeping the clutch engaged.

Is there anything I should be worried about with this? Can I screw up the transmission if I do this wrong?
1982 Yamaha Virago XV920 - Cafe racer mod in progress
- Handlebar mounts swapped for 1985 Virago XV1000 brackets
- Bars changed to 28 inch drag bars
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Re: XV 920 Handlebar swap -> clutch issues

PostAuthor: Flyingdog » Fri Jan 31, 2020 1:16 pm

firstoffive wrote: I'm thinking there is tension on the cable, keeping the clutch engaged.


If the cable is tight, it's holding the clutch pack in a "disengaged" state.


Clutch engaged: Clutch lever "out"...NO tension on the cable...clutch pack fully compressed (by way of clutch springs)

Clutch disengaged: Clutch lever pulled in...tension on the cable..clutch plate separated (by way of push-rod).

How did you "fiddle" with the cable? You got a manual? Have you tried loosening the cable by the clutch adjustment on the lever/bar side? Push-rod adjusting screw?

I would suggest getting a manual and doing a clutch adjustment, to begin with.
Last edited by Flyingdog on Fri Jan 31, 2020 1:19 pm, edited 1 time in total.
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Re: XV 920 Handlebar swap -> clutch issues

PostAuthor: Jake » Fri Jan 31, 2020 1:17 pm

The question to ask you is, what did you remove and what bars did you replace it with ?
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Re: XV 920 Handlebar swap -> clutch issues

PostAuthor: firstoffive » Fri Jan 31, 2020 8:57 pm

Jake wrote:The question to ask you is, what did you remove and what bars did you replace it with ?


I took off the original bars, ground off those stupid posts with teeth on them, and put on some bar risers from a 1985 xv1000, and drag bars.
risers.jpg


I've attached before and after pics so you can see what it looks like.

Before
IMG_6022.jpeg


After
IMG_0041.JPG
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1982 Yamaha Virago XV920 - Cafe racer mod in progress
- Handlebar mounts swapped for 1985 Virago XV1000 brackets
- Bars changed to 28 inch drag bars
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Re: XV 920 Handlebar swap -> clutch issues

PostAuthor: firstoffive » Fri Jan 31, 2020 9:12 pm

Flyingdog wrote:
firstoffive wrote: I'm thinking there is tension on the cable, keeping the clutch engaged.


If the cable is tight, it's holding the clutch pack in a "disengaged" state.


Clutch engaged: Clutch lever "out"...NO tension on the cable...clutch pack fully compressed (by way of clutch springs)

Clutch disengaged: Clutch lever pulled in...tension on the cable..clutch plate separated (by way of push-rod).

How did you "fiddle" with the cable? You got a manual? Have you tried loosening the cable by the clutch adjustment on the lever/bar side? Push-rod adjusting screw?

I would suggest getting a manual and doing a clutch adjustment, to begin with.



I fiddled with it only by physically moving the cable in its housing, the black stiff wire. I moved it around to get it moving right in relation to the new handlebars and mounts. I didn't do anything to the cable itself.
1982 Yamaha Virago XV920 - Cafe racer mod in progress
- Handlebar mounts swapped for 1985 Virago XV1000 brackets
- Bars changed to 28 inch drag bars
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Re: XV 920 Handlebar swap -> clutch issues

PostAuthor: drainplug » Sat Feb 01, 2020 10:59 am

I have an 83 with the same mounts and bars as you. Assuming you didn't re-route the cabie you probably have a sharp turn in the cable, which makes it bind in the housing. My cable is run from the lever behind the key switch to the gap below it on the right side, then turns back toward the left in front of the steering head, then down the left side of the bike. Hope that makes sense.
The main thing is to not have any sharp bends, a small amount of play at the lever and a well lubricated cable.
It can be a real pain trying to route all the stuff to where it needs to go through there without kinks but it can be done.

I have the same bars, same mounts and mirrors but I moved the choke lever to the left carb to clean up some of the bar clutter.
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Re: XV 920 Handlebar swap -> clutch issues

PostAuthor: firstoffive » Thu Feb 20, 2020 6:21 pm

Figured I'd update!

The cable issues have been largely fixed, and turned out to be my being a moron and accidentally creating some kinks that the clutch cable couldn't move through easily. I took all the lines and rerouted them so they moved freely and wouldn't bind at any points.

That being said, I am going to post up a topic for some brake issues I am having. I may have to take apart and clean the front brake system, which is not a project that I am super excited to undertake.
1982 Yamaha Virago XV920 - Cafe racer mod in progress
- Handlebar mounts swapped for 1985 Virago XV1000 brackets
- Bars changed to 28 inch drag bars
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Re: XV 920 Handlebar swap -> clutch issues

PostAuthor: Hellgate » Fri Feb 21, 2020 8:58 am

Congratulations! It's always a nice feeling to solve an issue like that.
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Re: XV 920 Handlebar swap -> clutch issues

PostAuthor: Flyingdog » Fri Feb 21, 2020 9:19 am

firstoffive wrote: accidentally creating some kinks that the clutch cable couldn't move through easily. I took all the lines and rerouted them so they moved freely and wouldn't bind at any points.


:GJ: Yep..it's those little things that'll stop ya dead in yer tracks. Most fixes are fairly logical..once you find the starting point.
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Re: XV 920 Handlebar swap -> clutch issues

PostAuthor: mark75 » Fri Feb 21, 2020 11:15 am

firstoffive wrote:Figured I'd update!

The cable issues have been largely fixed, and turned out to be my being a moron and accidentally creating some kinks that the clutch cable couldn't move through easily. I took all the lines and rerouted them so they moved freely and wouldn't bind at any points.

That being said, I am going to post up a topic for some brake issues I am having. I may have to take apart and clean the front brake system, which is not a project that I am super excited to undertake.


don't fret over brake system re-build issues too much. IMO the hardest part is 'bleeding' the system - only because it's so monotonous pumping the lever...

I would recommend a new brake-line (woven-steel brake line is best) while you're at it, especially if the original is still there.

even the master-cyl isn't a big-deal, just need pair of c-clip pliers as for "special" tools. be sure the tiny fluid-return-port is clean & not plugged-up.(very tiny hole in the bottom corner)
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so Laissez les bon temps roulez. just roll safely --- Semper Vigilans...always watchful

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Re: XV 920 Handlebar swap -> clutch issues

PostAuthor: Flyingdog » Fri Feb 21, 2020 11:36 am

mark75 wrote:. IMO the hardest part is 'bleeding' the system - only because it's so monotonous pumping the lever...


Why I always suggest, if you plan on doing all yer own motorcycle maintenance, using hand vacuum pump, reverse the pumps operation and "back-bleed" the new fluid. Besides...you can never have too many gadgets. If you think about it...air bubbles are the brake system's worst enemy (almost). Air bubbles "always" move "UP" and back-bleeding refills the system AND bleeds at the same time.

Ah crap..this thread is about clutches..not brakes...ah well. Amazing what four feet of snow will do to the mind. :cl:
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Re: XV 920 Handlebar swap -> clutch issues

PostAuthor: Hellgate » Fri Feb 21, 2020 6:53 pm

I recommend a Mity Vac, and Teflon tape to wrap around the threads of the bleed scews. Speed bleed screws are a nice add too. All three make the process a snap.
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Re: XV 920 Handlebar swap -> clutch issues

PostAuthor: Flyingdog » Sat Feb 22, 2020 4:00 am

Hellgate wrote: Speed bleed screws are a nice add too.


That's a pretty good trick, back-bleeding with a speed bleeder. :bg:
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Re: XV 920 Handlebar swap -> clutch issues

PostAuthor: mark75 » Sat Feb 22, 2020 7:02 am

Hellgate wrote:I recommend a Mity Vac, and Teflon tape to wrap around the threads of the bleed scews. Speed bleed screws are a nice add too. All three make the process a snap.



:look: that one looks like it might actually work - the HF 'knock-off' is worthless (might pull a vac. for 2 strokes before it dies)
>>> https://www.skf.com/mityvac/about/index.html

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Down the Valley of the Shadow,
Ride, boldly ride" ... E.A. Poe


Time flies >>> whether you're having fun __ :bike: or not :fan: ---

Any day above ground is a good day.
so Laissez les bon temps roulez. just roll safely --- Semper Vigilans...always watchful

"I hear and I forget, I see and I remember, I do and I understand." ... Confucius*

If you don't read the news you are not informed.
If you read the news you are misinformed.
... Mark Twain


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Re: XV 920 Handlebar swap -> clutch issues

PostAuthor: Hellgate » Sat Feb 22, 2020 7:41 am

Flyingdog wrote:
Hellgate wrote: Speed bleed screws are a nice add too.


That's a pretty good trick, back-bleeding with a speed bleeder. :bg:
Well worth the few extra dollars. All my bikes have them. When I bleed brakes I do all the bikes at once.
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Re: XV 920 Handlebar swap -> clutch issues

PostAuthor: Flyingdog » Sat Feb 22, 2020 9:17 am

Hellgate wrote:Well worth the few extra dollars. All my bikes have them. When I bleed brakes I do all the bikes at once.


Oh, I agree on the hand pump. Used one of the metal MityVac for ions..only use Speed Bleeder "once" on the truck. Must-a-been one of the lucky ones. Two outta the four leaked a drip every once-in-awhile. And..not thru the threads. Were even Russells. That was a well spent $20. Just as easy for me to push than pull the fluid. Which ever way the wind blows, I guess.
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