Today I replaced the clutch cable on my 03 Predator 500. Old one had the plastic liner of the steel cable letting go so was getting hard to use the clutch.

Put in new one, adjusted the slack and took it for a spin. Much smoother to shift. Also was able to stop and put it in neutral again. Before was really hard to get into neutral. Most times had to shut bike off and then shift to neutral.

But later on when driving around the farm checking our crops, every now and again I would have no clutch or barely. Engaging the clutch only half way through the course of the lever or almost at the end. Then pulling the lever a few times it would come back to normal. Even had 1 moment that I could not stop at all. What would couse the clutch to do that? Anything loose inside? Never had it before with the old cable but maybe because that was so stiff...

Any help is appreciated.

 

Could be weak clutch or springs. Also, if it's like motorcycle clutches (never messed with a quad clutch) there is a detente ball (possibly) in between the shafts that go from the shifter to the clutch basket. Sometimes it can get "welded" to the shaft when having to pull really hard on the cable to shift and make clutch engagement sketchy.

 

I replaced the clutch discs and springs a while ago because they were slipping badly. Couldn't put any power down. The friction discs were actually burnt. After the swap it has been doing its job properly. Full power no problem. Only heavy clutching because of the cable. That's why I ordered a new one to avoid burning up the discs again. But now this....

 

Oem or aftermarket cable? Could make a difference. At this point only thing you can do is retrace your steps starting on the clutch release shaft to the push rod and plate pusher. Manually with a pair of pliers see if the release shaft is pushing the rod and pressure plate feels like it has good outward tension and return power.Dirt Cheap Yamaha, Polaris, Suzuki & Kawasaki OEM Parts & Accessories – Cycle Parts Warehouse

 

Aftermarket cable but same length etc. Clutch works good most of the time and real smooth, but then once in a while it only engages half way or even at the end of its stroke

At this point i´m at a loss. seems like the problem needs to be inside the clutching mechanism? The old cable i couldn´t even move by hand...

 

Just retrace your steps on the clutch install. Could be something simple that jumps out at you.