[cdg097]

Hey everyone, I'm going to try NOT to send everyone on a wild goose chase tonight. Here is my current problem...while hooking up my clutch cable (new cable) to the bike, I've found that I am able to shift from neutral into gear, but when I pull the clutch lever, it does not appear to be engaging the clutch, because the bike stays in gear and will not roll forward or backward. I've tried reseting the clutch assembly on the case according to what the manual says, but it didn't make a difference. I've been told it's a possibility that my clutch springs were too tight, so after attempting to reset the assembly and also a few different cable adjustments, I took the right side case off (huge pain in the ass with the motor in the frame) and removed the clutch plates. Can anyone give me some tips to make the process go easier this time around and to ensure that I don't wind up having the same issue?

 

[willykiller]

Hey everyone, I'm going to try NOT to send everyone on a wild goose chase tonight. Here is my current problem...while hooking up my clutch cable (new cable) to the bike, I've found that I am able to shift from neutral into gear, but when I pull the clutch lever, it does not appear to be engaging the clutch, because the bike stays in gear and will not roll forward or backward. I've tried reseting the clutch assembly on the case according to what the manual says, but it didn't make a difference. I've been told it's a possibility that my clutch springs were too tight, so after attempting to reset the assembly and also a few different cable adjustments, I took the right side case off (huge pain in the ass with the motor in the frame) and removed the clutch plates. Can anyone give me some tips to make the process go easier this time around and to ensure that I don't wind up having the same issue?

When the clutch cover was on the engine and the clutch lever at the top of the cover was held tight to take all the freeplay from the linkage, did the timing mark on the cover and the lever line up............
The bolts that retain the springs must be tightened to 9 ft/lbs torque, they cant be overtightened using this procedure, the bolts are of a specific length and cant be overtightened............

 

[cdg097]

When the clutch cover was on the engine and the clutch lever at the top of the cover was held tight to take all the freeplay from the linkage, did the timing mark on the cover and the lever line up............
The bolts that retain the springs must be tightened to 9 ft/lbs torque, they cant be overtightened using this procedure, the bolts are of a specific length and cant be overtightened............

Yes, the timing marks lined up. I'm assuming you mean by "can't be overtightened" that if they are, they won't function properly, so make sure to tighten then to spec, and not that it is impossible to overtighten them. If so, then the problem must be that I overtightened them.

 

[dog86]

Yes, the timing marks lined up. I'm assuming you mean by "can't be overtightened" that if they are, they won't function properly, so make sure to tighten then to spec, and not that it is impossible to overtighten them. If so, then the problem must be that I overtightened them.

I don't think thats what he means.....

 

[Stuckey]

The bolts can only be installed so far before they hit the shank not alowwing them to turn anymore. They only stop at one point. Just like screwing in a lightbulb. So the only overtightening you can do would to stripping out the bolt or breaking the head off. So that wouldn't be your problem. That is what Willy was referring to...

 

[willykiller]

Yes, the timing marks lined up. I'm assuming you mean by "can't be overtightened" that if they are, they won't function properly, so make sure to tighten then to spec, and not that it is impossible to overtighten them. If so, then the problem must be that I overtightened them.

What I mean by the bolts can not be overtightened is that the bolts bottom out and they must be torqued to the 9 lbs, if you tighten the bolts more then 9 lbs, you risk breaking them............
The bolt is designed to set the spring at a predetermined height...............

 

[cdg097]

Ohhhh okay, I got it now. Okay the theory of me over torquing them goes out the window then. Hmm...I've got no clue then.

 

[infinitywholesale.aa]

Im having a similar issue. After building the engine, It will go into gear but the bike won't move even with throttle. I removed the shift arm out of the cover thinking it would allow clutch springs to travel more. Bit still It will not move in gear like clutch slipping. If start it in gear, it will try to move forward, but if you put foot in front of the tire and start it will not run over your foot Any ideas is appreciated

 

[willykiller]

Improper assembly of the clutch plates.

 

[CHIMBAZOID]

Improper assembly of the clutch plates.

Hey willykiller. Good to see you posting. It's been a while.
I assume the shop has been rebuilt and you are back to tinkering with the toys again?