So I just done the chain / sprockets on my NC35 and the clutch seems extra stiff.

When I was putting the front sprocket cover assembly back together it was no simple. Not sure how to describe correctly but the cover would not go flush as the bar into the engine seems to be proud, maybe 4mm.

I got the cover on and carefully tightened it down with the longest centre bolt. The clutch seems to be real hard to operate.

The way I see it, that would mean the clutch is being slightly pulled in all the time. Is this correct, seems to be a problem to me.

I also have absolutely 0 adjustment, on either the lever or by the engine. (will post some pics soon, just don't have signal on my mobile at work).

Lever:
engine:

Also, I am pretty sure the engine side is wrong, there is no way to adjust it at all.. Anyone know what is going on here?

dogmatic69 wrote:Lever:
engine:

Also, I am pretty sure the engine side is wrong, there is no way to adjust it at all.. Anyone know what is going on here?

not keen on those levers copared to OE ones... but anyway.

Where are the nuts to lock the cable to the clutch cable holder lever at the engine side? That is why you ahve no adjustment, im surprised it ever worked at all.



You can see here in a cable there are two nuts you tighten each side of the bracket to lock the cable into place.

here is one side of the bracket holder with a nut on it (images from StrayAliens post)



and another of a proper clutch lever with the proper Honda bracket to adjust



finally it sounds like you havent got the sprocket cover on properly either, the lever that is pulled by the cable can becaome dislocated and hard to refit until you reset it, dont just force it on by tightening the screws it can damage the case and the clutch lever, worth while rechecking that but eitherway you need to get a clutch cable with some nuts on it, or even find some you can put on that cable.

get the cable sorted out and the sprocket cover rechecked andshould be good to go

That was kind of my point about the adjustment, it does not seem like there is enough room for a nut on there (got the bike without a nut). also the clutch seems to work fine and bites right at the top, only need to pull it in 1/4 way for it to work

Looking at those pictures the clutch cable is def the wrong one. The one I got is 100% straight and mostly fowls the clocks. Will have to look at getting a new one.

Been doing some thinking about this issue this evening. The only thing that seems to make sense is that the clutch was probably worn, and slipping. so prev owner took the nut off to give it more life...

If I added the nut back now the clutch would be half pulled in, and probably slipping if anything.

I took the cable off and it is pretty much free, not binding at all. Guess I will have to invest in some new clutch plates :/

Neosophist wrote: ...finally it sounds like you havent got the sprocket cover on properly either, the lever that is pulled by the cable can becaome dislocated and hard to refit until you reset it...

I'd go along with this, it is very easy to get that lever unseated when refiting the sprocket cover!
Pull the cover off again and double check it's how it should be in there.

Man, on the way to work this morning the clutch was slipping :/

Will do the whole lot come end of the month...

dogmatic69 wrote: . . . Looking at those pictures the clutch cable is def the wrong one . . .

Well that's part of your problem then, get the correct one before you blow £££ on a new Clutch

As for the Stiffness, check the Dowels are in place between the cover and the casing.
If they've been lost/removed, then the cover won't align properly, which would most likely cause the problem you're having due to the release mech not being concentric with the release rod.