Have a totalled 929 I picked up for cheap and am working to get back on the road. Getting stuck now and need some help! Clutch lever has no resistance. Pulls in with no effort and does not return. New cable. New spring at engine end of cable. I did have the entire engine apart to replace the lower half of the crank case due to a crack from being dropped. All the clutch plates and basket seemed fine and I believe it all went back together properly. I can move the spring at the engine easily by hand. I have another 929 that is in perfect shape, and I can't move the spring on it by hand at all. Would this then be an internal issue with the clutch? Any thoughts or advice is much appreciated! Thanks!

 

Hi and welcome to the forum. Are you saying you only replaced the bottom half? As for the clutch, my first thought is that it's missing a plate.

 

Yes, just the bottom. Only missing a plate if it was to begin with. Put back in what I took out.

 

Umm, I'm not sure if you're aware or not, but the upper and lower halves of the crankcase are a matched set. They machine the 2 surfaces where they bolt together, then bolt them together before machining the holes where the crankshaft and transmission components sit. That is why the manufacturers only sell the set and not a single half of the crankcase. There is a good chance that the bearings will wear out or fail due to misalignment. You might want to reconsider before you run the engine. Just a word of caution.

 

Could that have anything to do with the clutch issue tho? And would that be an issue over time versus now? It shifted thru the gears ok when I put it back together.

 

No, I don't think that would affect the clutch lever not having any resistance, or very low resistance. I'm just thinking that something is missing.

 

Actuator in the clutch cover is not engaging the lifter pin or the actuator is broken. The 929 clutch was recalled and they replaced the actuator, clutch basket and few other pieces. Think the recall is still active.