More clutch problems!!! post rebuild

got the starter clutch fixed, got a new basket, hub and all the goodies that go with it. After I got it all back together, it seems like the push rod isnt pushing right. I Checked for the ball, it was there. There is also like a mile of play in the clutch lever, even with the cable all the way in and out nothing changes that part. If anyone has any other idea??? I am kinda leaning towards maybe I have an extra washer in the assembly?? that sound plausible?

Anything is plausible with these bikes.

Maybe this will help you:

Do you have a manual to help?

You could have the clutch cover out of allignment, with the rod not properly seated in the cable pull actuator.

TeK9iNe wrote:

Anything is plausible with these bikes.

Maybe this will help you:

Do you have a manual to help?

You could have the clutch cover out of allignment, with the rod not properly seated in the cable pull actuator.

Do have a clymer manual, put everything back the way it said and in the order it said. There were a couple of washers that were listed that werent on there to begin with. The problem is that It doesnt show the specs of the washers. I think it may just be washers in the wrong order, or possibly an extra in the wrong place.

Sometimes if you have the clutch worm gear arm down in the cases off a tooth or two, the clutch won't work right. You can try moving it a tooth or so to see if it makes any difference. Time consuming but I have done that before and it drives you crazy trying to adjust the clutch when it is like that.

racer54 wrote:

Sometimes if you have the clutch worm gear arm down in the cases off a tooth or two, the clutch won't work right. You can try moving it a tooth or so to see if it makes any difference. Time consuming but I have done that before and it drives you crazy trying to adjust the clutch when it is like that.

Sorry not real familiar with all this still. Where is the worm gear? I dont remember seeing one of those in the manual when going through all of that.

It's actually the "lever" your clutch cable is hooked to underneath the cover on the left side of the bike. Just follow the clutch cable down and you will see it. Beings it runs in grooves, it can be installed in just about any angle but if you get it wrong, it puts the lever arm at the wrong angle to get necessary leverage when you pull in the clutch and what feels like a bad clutch, might just be that piece in the wrong slot. I think the manual should tell how to install it right....I think. I did it wrong once and it took a little to figure out what I did. This is a possibility...could be something else but it is something to check.

So far no luck with any of this... Did find out that there was a washer missing that caused the problems first mentioned. After finding the washer, I had the clutch adjusted just about right then the 3 bearing roller popped and slipped out of the slots. Several attempts at this and I decided that the new EBC clutch springs were just too much. Put old springs back on and now I cant seem to manage getting the adjustment right. The lever either has half a mile of slack and the clutch stays engaged no matter what, or there is not enough slack on the lever and the clutch stays disengaged no matter what. Please give me some ideas on what to do, I have been playing with the tension for about 4 hours now.