Clutch adjustment maxed

SVandal · Sep 22, 2007

I just put in new clutch plates and I had to adjust the cable all of the way to the stops. Any ideas on why this would be? I have an aftermarket perch that came on the bike that may not have enough initial pull, but I was hoping that someone would have an idea about what else may be causing it. Also, with the clutch lever pulled if I put it in gear I can not roll back and forth.

Thanks

craig_enid · Sep 23, 2007

Clutch perch adjustment, in-line clutch cable adjustment, clutch cable/case attachment point adjustment, washers inside the case on the push rod thingie adjustment.
You've worked them all in the way needed to get slippage/release of the clutch pack?
As a test, I've put vise grips on the actuator arm and bypassed all the clutch cable stuff.
(put it in gear, reach down and manually disengage the clutch, by hand, try to roll bike)

SVandal · Sep 24, 2007

I'll have to try that when I get back from travel. I finished the bike in time to leave for a week for work. Worst case I'll have to pull the clutch cover back off and ruin a gasket, but still cheaper than a new perch or cable. Is it typical to have more than one washer on the push rod?
Thanks for the suggestion.

SVandal · Sep 30, 2007

Ok, tried the actuator arm to full travel with a crescent wrench and still not slipping. I soaked the friction plates for 2 hours in new transmission oil to make sure that the clutch didn't freeze. Is there something else that could be causing this? Thanks.

ctdyno · Sep 30, 2007

sometimes bikes wont roll with the clutch in that easily, my bike doesnt

SVandal · Sep 30, 2007

When I started it and put it in gear it killed the engine. The clutch basket looked fine when I was putting in the new clutch. Though I should note that the previous clutch had this problem as well. One thing I noticed when taking it apart was that the outer clutch plate was set in a different set of grooves from the others, is it supposed to be this way, or should all of the clutch plates be set in the same grooves?

jason33 · Oct 1, 2007

no sounds like the basket is wore out- the tabs the plates slide in and out of get grooves wore in them ,and they need filed smooth if possible (quick temperary fix)
so the plates will slide open right-
check the arm for the right adjustment- , dont use too thick of oil

SVandal · Oct 2, 2007

Well, finally took it out tonight. The clutch would still try to grab when the lever was fully pulled, but it got better. I am going to pull the cover and add a washer. Thanks for the ideas.

Green Hornet · Oct 4, 2007

I would bet the washer between the inside of the basket & clutch plates slipped out of place during install. Take apart & you will see what I mean. I did it in the spring & the bike had the same syptoms....Oh Yeah, the outer plate is set in a different position

SVandal · Oct 5, 2007

I doubled checked that one on install to make sure that I didn't miss it. Instead I added a couple of the washers for the actuator spacing. With 2 I now don't have to expand out all of the adjusters, it still wants to grab somewhat, but at least I have a solid feel to the clutch now. I'll test it out today and see how it goes.

Green Hornet · Oct 5, 2007

The washer can slip out of place when installing the basket. Re-Check, take the added washer out & see if it works.

SVandal · Oct 6, 2007

I had the engine on a bench laying on its side when I put the washer over the shaft inside the basket. It would have had to defy gravity to slip out.

Clutch adjustment maxed

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