looking for instructions on how to replace clutch lever

[edit] damn, screwed up the title. I meant clutch cable, but now my mechanical newbishness is totally starting to show through and I'm wondering if there even is a clutch cable on my `91 750. All I know is it's got the symptoms of needing a new clutch cable. Won't fully disengage, and a really long pull. If you leave your hand off the throttle, with the clutch fully in, and switch from neutral to first it immediately stalls.

 

Doesn't the '91 have a HYDRAULIC clutch???

 

Yeah, you're right. I figured that out after testing and finally got ahold of a copy of the maintenance manual. Thanks. Sorry for the newbishness.

 

No problem.

So now that you have a manual, let's narrow down what we have as an issue here...

From what you've described in your initial post it sounds like the slave cylinder or the master cylinder is not doing it's job. Do we have any leaks in the system, especially at the banjo bolts?

What color is the fluid in the reservoir? New brake fluid is a light yellow, and transparent. As it ages, it gets more brown, and cloudy. If it is dark and cloudy, I would suggest bleeding the system and see if that cures the problem. This would be my first step.

If this does not fix the problem, I would remove the slave cylinder (leaving it attached to the hydraulic hose) from the front sprocket cover and inspect it for leakage. I'd then disassemble it and clean it thoroughly, possibly replacing the seal if necessary. Make sure that the bore is smooth and has no nasty sludge built up on it.

If this does not fix the issue, I'd then move to rebuilding the master cylinder. Kits are available pretty much everywhere, as almost all Honda clutch master cylinders are identical internally.

Keep in mind that bleeding this system is a MAJOR bitch and takes a lot of time and patience. If any of this is over your head, take it to a bike shop.:lever:

 

I can check fluid but i'd probably take it somewhere to be bled as i don't have much equipment, or a garage... I noticed that the new OEM clutch levers have some sort of little adjuster on them (mine doesn't). Might this also be a simple thing that would help somewhat? I'm not thinking it would really fix the problem but at least alleviate it a little and be good to have in the future.

 

The OEM levers have a small degree of adjustability for reach, but will not fix your problem.

I'd suggest taking it somewhere. :yield: There's a hydraulic issue of some sort going on.