ummmm why me

2000blasternewb

New Member
Aug 4, 2009
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FT. Sill, OK
Ok so I always have this problem of things always come apart easier than they go back together. Started putting my motor back together. All was going well till i got to the clutch. First I realized the little brass ball wasnt in the shaft. I will have to take it apart tomorrow to replace that. Also I have it to where I can work the pads out by hand and move them around. (you can see this in the pictures) Also in the another picture you can see that the gear of the clutch basket rubs against the balancer gear. And my last thing is that when I turn the clutch lever nothing happens with the clutch basket or nothing. Any opinions on whats wrong? Yes I know Im a dumbass for not paying more attention to the removal. Lesson is fully learned there.

2ykmfr5.jpg

This is the clutch as it sat right after I put it back together. The set screw is all the way in, that was how it was when I took it off. Also the screws that hold the springs are all the way in also like how I took it off.

fa5uz5.jpg

This is what I was talking about, that I can move the pad out from under the plate.

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This is showing that the basket gear is rubbing agains the balancer gear.

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This is me trying to show that it is very easy to move the clutch lever by hand and that nothing happens when I move it.

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Just another picture of my clutch
 
Sorry man, I don't know much about clutches.. Wish I could help... Good luck though man! Hope it works out for the best.

Oh and I had that same problem when I was stripping down my entire bike, I paid about $25 total in bolts and nuts that I lost lol.
 
take out all the bolts in the clutch an turn the preasure plate till it falls into the groves it looks like in the pictures that its not straight the preasure plate should be farther in than that i believe it should push the clutch plates an friction plates together when the springs are in i did the same thing when i put my clutch back together
 
also you wont able to operate your clutch with your hand like that, you need the leverage the lever gives.. mine does the same thing and i was worried that my clutch was bad but its normal.
 
There are dots on the pressure plate and the clutch boss that need to line up. The steel ball needs to be in there to work properly. There is a wavy washer that needs to be installed with the correct friction plate to let the basket accept all the components and there is a spacer that needs to be installed behind the basket to keep it from rubbing the other gears. A manual will help.
 
thank you everyone for the help. i do have a manual pitboss, just hard to read the downloadable version sometimes. its not very detailed. I didnt even know about the brass ball until I saw it laying on the bench lol. I will be working on it soon. Thanks