01 yamaha blaster clutch

[cpcoop71]

my 01 blaster clutch was not working when I got it. it was stuck in gear and I could drive it but not use the clutch. my actuator arm has been sticking forward. I got new steel and fiber plates and springs. soaked them for 24 hours.

I installed in proper order according to the tabs on the steel plates. I lined the pressure plate up also. it was still stuck in gear and the actuator arm was still sticking forward.

I took it apart and could not find the ball . tipped it on its side and no ball came out. I got a new ball and outer rod and installed them. The clutch now sticks so that it won't go forward in gear and if I ran it then im sure it would just rev and not go forward.

I have played a bit with the adjustment rod in the center of the clutch. I have lined up the actuator with the line. The odd thing I notice is the actuator (shifter side) seems to rise out of the case a bit when it goes forward. I can move the arm backward but it takes a little force. spring seems ok. any ideas? Thank you in advance.I:I

 

[EZRider76]

Clutch arm is stuck forward??? Did the PO rebuild it and assemble it wrong?

 

[cpcoop71]

po? not sure if it was assembled wrong but it goes forward fine and takes a little force to move backward. As soon as weather clears up I am going to pull off cover and have a look.
something might be broken in there.

 

[EZRider76]

po? not sure if it was assembled wrong but it goes forward fine and takes a little force to move backward. As soon as weather clears up I am going to pull off cover and have a look.
something might be broken in there.

PO-Previous Owner. So, now that I've reread what you wrote, you squeeze the clutch fine, but it doesn't release fine? Does it do the same thing when the cable is disconnected? Check both the cable and the clutch arm. Try moving it by hand and seeing what happens. If the cable is fine, maybe your springs are shot. Could be something hanging up on the Clutch Basket...were the channels for the friction plates smooth or rough? Should be smooth. Anyhow, start with small inspections and work you way up to disassembly. I would definitely try checking inside the clutch cover though after you test the cable for stickiness and the clutch arm freeness.

 

[bagds101]

Might be the shifting rod or forks

 

[cpcoop71]

just got a brand new motion pro clutch cable. it sticks no matter if the cable is connected or not. when I move it backward It is hard to do it by hand. I usually use pliers. its like something is sticking inside.

BTW the bike shifts really well. its just a clutch problem.

 

[EZRider76]

If I remember correctly, you should be able to push that thing forward with your thumb when the cable is disconnected. Take clutch cover plate back off and reinspect. I know you say you did everything right, but I can look at the same drawing all day wrong and see no mistakes, come back the next day and find 5 things wrong with it. With the clutch springs removed and holding the clutch plate with one hand, try pushing the lever with the other or have someone else move it, then let go and push on the cover plate to see if it returns. It could even be a broken gear or a chip of metal somewhere in the clutch. Eliminate the easy stuff first. Check those things first, if all is well with that, start disassembling...or bump this thread at about 9pm for some of the really sharp guys to give their input. AWK08, Slickerthanyou, Yamaha28, Sicivicdude (he's sharp as a tack), Blaaster...try to get their attention.

 

[EZRider76]

Also...have you seen this yet? It's a damn good place to start.

http://www.blasterforum.com/general-support-17/downloadable-yamaha-blaster-manual-17325/[/QUOTE]

 

[cpcoop71]

I have a copy of the manual online. Im not saying I put it back together correctly because Im know for mistakes. I wanted to list the steps I took in order to get it back together.
I will pull it back apart in the morning and try again. I will also look at the actuator and see if it has any problems.

 

[EZRider76]

I have a copy of the manual online. Im not saying I put it back together correctly because Im know for mistakes. I wanted to list the steps I took in order to get it back together.
I will pull it back apart in the morning and try again. I will also look at the actuator and see if it has any problems.

Sorry, confused posts. I was responding to yours, but I was thinking you said you knew you put it together right. Anyhow, stay with trying what I've described and let us know. I hope that you find it is a simple fix and you don't have to tear too much apart.

 

[cpcoop71]

lol. I knew what you were saying. I have quite a bit of experience with engines but very little with clutches. Yeah Im going to look at it again and see whats up. thanks for the help.

 

[Larry's Shee]

I didn't read all of this but I'll bet the ball is welded to the rod and now you have two balls . Unfortunately you may have to split the cases to drive the rod out of the shaft.

Ball welding can be caused several ways. Long downhill with clutch pulled, or anyother extended period of pressure on the ball. X(

 

[Blaaster]

Or lack of lubrication on assembly!

 

[cpcoop71]

yeah I understood what you were saying though. if the rain stops I will look at the situation again today.

 

[Larry's Shee]

Did you read manual for clutch assembly? Gotta do it correct

 

[blasterdemon7]

I would check the rod that touches the arm. It could be bent or crapped up making it stick. Your best bet is to start checking each part of the clutch system to find what's wrong.

 

[cpcoop71]

thats the only thing i didnt check. that will be next. I did look at the manual. all i removed so far was the plates, outer rod, rod nut/washer pressure plate with the 5 screws/washers.

 

[slickerthanyou]

That ball bearing has a habit of falling out sometimes. with the cover off, and everthing disconnected, pull the clutch lever does the pressure plate move away from the clutches about 1/8" or so? If not start with internal adjustment. make sure the cable is disconnected from the clutch arm or the lever before you do this.

 

[cpcoop71]

finally a break in the rain. got out there and moved the carb. gave the clutch actuator a tug and it came all the way out. I would think the inner clutch rod isnt there but wouldn't the outer rod fall down inside?

 

[cpcoop71]

oh and I tipped my bike to the side after pulling the outer clutch rod out and the inner one is nowhere to be found. any ideas?