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New clutch

J

jfrench

Forum Newbie
Can’t figure out what I’m doing wrong
replaced the fiber plates and steel plates. New springs.
pretty straight forward, right? Made sure the bearing assembly was correct and not missing anything. Put the hub back on and made sure it was positioned correctly, springs and bolts installed.
tried the clutch leaver, goes straight back to the bar. There’s no engagement what so ever. Same number of fiber plates and steel plates, I’ve done this before with out this problem. HELP please!
 
"Clutch lever goes straight back to the bar", there's no engagement what so ever... With clutch pulled in the clutch ain't supposed to be engaged...I can't tell what you're feeling through the lever. When you pull the lever in, do you feel the resistance of the springs on the pressure plate? do the springs pull the lever back out as normal, if not, somewhere you aren't connected to the pressure plate.
 
Something wrong with the cable or release mechanism. What bike?
 
rphillips said:
"Clutch lever goes straight back to the bar", there's no engagement what so ever... With clutch pulled in the clutch ain't supposed to be engaged...I can't tell what you're feeling through the lever. When you pull the lever in, do you feel the resistance of the springs on the pressure plate? do the springs pull the lever back out as normal, if not, somewhere you aren't connected to the pressure plate.
Click to expand...
No there is no resistance from the springs. With the clutch plates and the clutch Hood assembled, ready to install the cover, I can pull the clutch in and see the actuator (The small plunger that has the thrust washers and the bearing in the middle move with out engaging the hood. There seems to be too much space between that push rod and the Clutch hood. I check to make sure there isnt suppose to be a ball bearing between the actuator and the push rod to take up the space if all of this makes sense
 
Last edited:
I can't remember how those push rod ones work as it's been over 15 years since I worked on one but on the other style it's simple a case of not having the mechanism rotated to take out all the slack before putting the arm on the splines. Vaguely recall there being something you need to do to achieve the same thing on the pushrods...
 
There is a ball and ramp mechanism in the engine cover, that pushes the push rod. If that was taken apart, it's possible that it's currently out of position. There is a threaded adjuster on this mechanism also. The factory service manual has some info, but not a lot.
 
Thanks to all and I hope to get to the bottom of this
going to stack up the old set of plates and fibers up vs the new and see what I get? Also check the adjuster on the left side to make sure nothing is out of place
 
Well the mystery has been solved.

I checked the stack height of the old fiber/steel vs new and the new was almost .165 taller than the old.
the new steel plates were .017 thicker than the old
The fiber plates were with in a couple of thousands of each other.
I put the old steel plates with the new fiber and bingo, every thing is working like it’s supposed too
thanks
jim
 
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