clutch

[hockey fan]

Hey Guys

Ive been around the site for awhile at least long enough to know you guys have alot of information.
I have my bike tore down for a starter re install(broke the jackshaft) starter works fine but putting everything back together since pipes were off. I thought it would be a great time to adjust the clutch. It had been trying to crawl slightly.
well over the past couple of days I have done the step by step process with the pushrod, way to many times to keep track of. The clutch just wont disengage, done this over and over. If i put the bike in neutral it roles just fine. I am thinking there is another problem I took the clutch cable assembly apart and put it back, all is fine there, adjust the cable to the 1/16 to 1/8 inch slack at the handle. Run the push rod in till reach preasure then back off push rod 1/4 turn 1/2 turn 3/4 turn 1 full turn nothing changes. the push rod is moving in and out with the clutch lever being pulled, I am looking for another explanation or suggestion which direction to go from here.... Dealer is out of the question this time of year to far and too many mts. besides that i am a stubborn s.o.b This isnt going to beat me.:bang:
If anyone has a suggestion please don't hesitate to push me in a direction

thanks everyone

 

[phatchopper300]

Did you loosen the cable all the way out that is on the down tube. Once this has slack in the cable readjust the rod again then tighten the cable again. That should get it.

 

[hockey fan]

Did you loosen the cable all the way out that is on the down tube.

Yes absolutly put the adjustment all the way so maximum slack

 

[phatchopper300]

Yes absolutly put the adjustment all the way so maximum slack

Hummmmm....I am sure someone will chime in and have a better solution or maybe I missed something. Love the paint "money to burn"

 

[hockey fan]

I just wonder if when the jack shaft broke on the starter if there wasnt another issue that caused that, and this, that has been un diagnosed. I am going down to the store to get some primary oil and such, think i will start on that side to make sure i dont have a broken clutch housing like a few of the photos here and also check the clutch hub nut. past that i am clueless.

 

[phatchopper300]

Yep I would check and open the primary cover to see if part of the jackshaft has lodged behind the clutch. Its worth looking into.

 

[woodbutcher]

if it is creeping, have you checked the "infamous" loose clutch hub nut. do a search and you will find all kinds of info on this subject.

 

[BBChopper]

if it is creeping, have you checked the "infamous" loose clutch hub nut. do a search and you will find all kinds of info on this subject.

X2~~:2thumbs:

 

[hockey fan]

thanks everyone it is greatly appreciated me being just a dumb concrete finisher and all.
another opinion is really appreciated

 

[troppushcet]

If you are going to remove the clutch nut? I would go ahead and remove the clutch assembly. This way you check the six bolts on the back of clutch ( 24 ft lbs ) and also you check your left side main bearing by holding the main shaft and checking for up, down, side to side and in out movement. If there is? Then your transmission bearings are bad. And could be why you starter shaft broke and clutch issues. If all is good then before reassembly. Look inside the main seal, if you see a brown o-ring? Remove it. NOTE... when your clutch nut is loose or clutch assembly is removed, you will see transmission fluid coming out of the main seal...this does not mean the seal is bad.
Now...after the clutch assembly is back on and before you tighten the clutch nut and add red loctite. Tighten the clutch nut to 150 ft lbs. If your main shaft moved? This will put it back in place. Then remove the clutch nut add red loctite to the threads of your mainshaft, tighten to 100 ft lbs.
On your adjustments... before you put your outter primary back on. Adjusting your clutch push rod with one hand and the other hand touching your throw out bearing in the center of clutch assembly. Turn the push rod in until you feel the rod touch the throw out bearing, then back it off 1/8 to under a 1/4 turn. Cable slack should be no more than 1/16. Good luck to you!!!

 

[X-ray Doc]

One other thing to check if you remove the clutch plates is to check the steel plates to see if any are warped, got hot (blue colored) and are now bent and not releasing totally. Stack all the plain steel plates on a level surface and then look to see if there is any space between them, daylight. if they do not lay flat on each other this could explain the clutch not releasing completely.

 

[troppushcet]

Good call. If you do that? You should also check you pressure plate too. That is the aluminum plate up against your fiber plate. You want to look at the flat side and make sure it is flat all the way, if see a small sharp lip or waves on it. Replace it.

 

[hockey fan]

The Clutch Hub nut was loose about a full turn and a half before clicked at 100- ft.Lb
need a bigger torque wrench at the moment. but no problem pick one up at work
will torque down by the book and put the throw out bearing on and see if problem solved every thing else looks good in there didnt take clutch pack apart and check plates yet. but will do that and check everything in there while it is open ... any other points to look at the tensioner looks good not a great deal of wear still see most of the chain. the chain lash seems to be in the right ball park.
there was very little metal fuzz on the drain plug maginate felt like maybe three tiny pieces couldnt see them but could feel them with fingers ... but they could be the size of a grape and i wouldnt be able to see them unless got back ten feet or so. Thanks fellas
If any time we hook up at a rally or show the first adult beverages are on me....

 

[BBChopper]

The Clutch Hub nut was loose about a full turn and a half before clicked at 100- ft.Lb
need a bigger torque wrench at the moment. but no problem pick one up at work
will torque down by the book and put the throw out bearing on and see if problem solved every thing else looks good in there didnt take clutch pack apart and check plates yet. but will do that and check everything in there while it is open ... any other points to look at the tensioner looks good not a great deal of wear still see most of the chain. the chain lash seems to be in the right ball park.
there was very little metal fuzz on the drain plug maginate felt like maybe three tiny pieces couldnt see them but could feel them with fingers ... but they could be the size of a grape and i wouldnt be able to see them unless got back ten feet or so. Thanks fellas
If any time we hook up at a rally or show the first adult beverages are on me....

Dont forget the Loctite!!!:2thumbs:

 

[woodbutcher]

If you are going to remove the clutch nut? I would go ahead and remove the clutch assembly. This way you check the six bolts on the back of clutch ( 24 ft lbs ) and also you check your left side main bearing by holding the main shaft and checking for up, down, side to side and in out movement. If there is? Then your transmission bearings are bad. And could be why you starter shaft broke and clutch issues. If all is good then before reassembly. Look inside the main seal, if you see a brown o-ring? Remove it. NOTE... when your clutch nut is loose or clutch assembly is removed, you will see transmission fluid coming out of the main seal...this does not mean the seal is bad.
Now...after the clutch assembly is back on and before you tighten the clutch nut and add red loctite. Tighten the clutch nut to 150 ft lbs. If your main shaft moved? This will put it back in place. Then remove the clutch nut add red loctite to the threads of your mainshaft, tighten to 100 ft lbs.
On your adjustments... before you put your outter primary back on. Adjusting your clutch push rod with one hand and the other hand touching your throw out bearing in the center of clutch assembly. Turn the push rod in until you feel the rod touch the throw out bearing, then back it off 1/8 to under a 1/4 turn. Cable slack should be no more than 1/16. Good luck to you!!!

definitely follow these instructions. :2thumbs::2thumbs:

 

[PurpleDog]

definitely follow these instructions. :2thumbs::2thumbs:

+2 - else you'll be doing it again. Make sure the threads are cleaned brake cleaner or the like. I'd hit that sucker with an impact after I torqued it - for good measure...

 

[hockey fan]

Been playing with this clutch thing off and on in free time took the clutch assembly apart inspected everything as advised steels look almost brand new clutch fibers look good (to me anyways) didnt see any thing 0ut of ordinary restacked the clutch pack on the bike after i had the clutch reassembled with out pushrod snugged up or preasure plate on, the wheel spun with minumum drag. attached the spring and torqued down adjusted clutch with pushrod etc.. it goes back to the same situation were the wheel acts as if the clutch is not pulled and engaged in gear... im confused think i will re assemble the bike take it for a test run and see what is up the worst thing is i take it back apart i guess.
spoke with baker yesterday and the tech support fella suggested to put it down on ground have someone push me backwards and engage clutch to break pack loose but i went the unstack rout,which was also discussed, to free up the plates since am doing this by my self and is way to cold this week
also have a much more experienced fella i bribed with a few cold ones coming over sunday to give me a hand to make sure i am on the right track
will up date with what i am doing wrong if any thing when solutions are discovered...

 

[Moespeeds]

It's normal for the wheel to spin when it's running in gear, with the clutch pulled, and up in the air on a lift, etc. If it is creeping in gear once down on the ground with you sitting on it, and you have tried over and over again to get it properly adjusted, pull the primary cover and physically watch the clutch plates move when you pull the clutch. Adjust it with the primary cover off. Somewhere there will be a spec on how much separation you should get, check with Baker on that. Have you checked to make sure the clutch pushrod isn't broken or worn? Also make sure the throwout bearing spins freely.

 

[hockey fan]

Problem solved wish i could tell you some technical dribble about what i had to do to fix it but not happening
Dont have a clue took the clutch pack apart went through each friction plate and steel one by one again. didnt find anything put everything back together again just exactly like i did the previous three times adjusted the clutch exactly the same i had must have done two dozen times and the thing works just like new didnt do squat that i know of different,, damn gremlins
the good news is its breaking traction running through a couple gears with out jumping down its throat! way cool, smiling from ear to ear when i rolled in. thanks Guys

 

[phatchopper300]

Who knows those gremlins! Glad you got it up and running-Now if this damn snow would melt and get the temp up to 45-50 I would go for a ride myself.