Replaced clutch, now issues with cable

[coggonbrien]

I replaced my clutch. first time pulling the handle i did so with the timing cover installed but no oil (thought I would acuate it not running to verify it installed correctly before wasting oil). the handle pulled hard and will not return to it's home position.

Any ideas?

Thanks,
David

 

[Blaner]

is the cable bolted down onto the cylinder? on the left there is a bracket. make sure its under the cylinder nut

 

[coggonbrien]

yes, i never removed the cable. here's the order of what i did:
removed kick start
removed clutch cover bolts
removed bolts holding brake pedal as i could not remove the cover without doing so
removed cover and let oil drain
cleaned inside of cover with brake clean, blew out, and wiped
removed 4 bolts and springs
removed center bolt and pressure plate
removed friction plate and clutch plates as complete stack
started installing new frictions/plates in same order (they were soaked for 3 days in new oil) reinstalled clutch boss spring in correct order
reinstalled pressure plate
installed new springs with old hardware
installed center bolt/washer
installed kick start assembly
installed new gasket/clutch cover
ran all bolts down
torqued all bolts (started on opposite ends and made a complete circle alternating
reinstalled kickstart pedal

pulled clutch handle with no oil to test
cable stuck
assembly does turn as expected with kick start
David

 

[Blaner]

search for a manual on here, i thinks you are in need of one to help prevent these unnecessary problems

 

[Antec1200X]

did you line up the marks on the inner clutch basket with the center cover?
a guy had a simular problem

 

[coggonbrien]

that's what i missed, i didn't see the marks. thanks antec. any other suggestions while i have it opened back up?

 

[Antec1200X]

i cant think of anything besides lining up those marks.

 

[coggonbrien]

to close this loop for any searchers out there, i relocate the pressure plate to match the dots and that took care of it.

David

 

[slickerthanyou]

Nice Job NOOB! !

 

[coggonbrien]

you can take back your compliment, after being sick the last 3 days i finally finished draining the old fuel, replaced the fuel filter, and a new spark plug. fired it up for the first time in 6 months and......same issue as before the clutch swap........i am getting full travel out of the arm coming up out of the case but the clutch is not grabbing. thoughts anyone??????

 

[coggonbrien]

alright found these directions from quicker than you, will try tomorrow morning after work:


1. loosen the outer center nut on the pressure plate almost all the way off
2. hold the clutch lever (the part that the cable hooks onto in the motor) and gently push it towards the front of your bike to relieve the spring tension
3. Now with a small phillips turn the center shaft in which ever direction it takes to align the pointer marks up as you are applying a little pressure to lever shouldn't take many turns you will feel it move. [usually clockwise]
4. When it is aligned, let the lever go it will go off the arrow due to spring tension that's ok. Keep your screw driver on there and take your wrench 10mm and tighten the center nut down snug while holding the center rod tight so it doesn't move. (I used blue locktight also)
5. Now take a socket and tighten it down good but becareful you dont overtighten it and snap it just a good snug tight is perfect. 5 ft lbs is what the manual says. 6. Put the cover back on, make sure your spring for the kick gear is in the hole when you do this or you'll be replacing some more parts down the road (experience talking here!).
7. attach the cable back up and adjust that just until you feel the springs on the pressure plate start to hit, then back off 1/8 turn and try that, ya may need to play with the adjustment on the handle bar lever as it warms up.

 

[lowkhalbalr]

the center adjustment shaft is 2 piece with a ball bearing in between. the adjustment shaft should be tightened til it touches the ball bearing then backed off a 1/4 turn maybe even an 1/8th.your just trying to take pressure off the clutch. the bike doesnt go anywhere b/c the clutch is to loose. it needs to be like prom night, nice and tight.

 

[lowkhalbalr]

the clutch has to be engaged via actuator arm, in order to do the job correctly. pulling the lever will not do it alone. go to home depot and get a big ass zip tie and use it in conjusnction with vise grips. this is the best way to do it without someone elses help. pm for any questions. happy to help however i can.

 

[coggonbrien]

is it possible for the ball bearing to fall out with the shaft still assembled? i've got my nut almost falling off the threads, unless i'm supposed to be going the opposite direciton

 

[coggonbrien]

well i finally killed this one today with internal clutch adjustment. what's the worse thing that would happen if i set the screw too far in? pre-mature clutch failure? the gears hold tight going down the road and the clutch does release nicely.

David