Hello last week i installed the clutch basket back on the bike and i used all of the correct hardwaer and spacers just like it showed in the manual. And today i installed the clutch after leaving it over night in oil and the problem is that it does not want to disengage! The pressure plate is not moving at all and the lifter pin is moving freely... Any opinions what might be wrong?

 

Did you over torque the bolts holding the clutch springs and the pressure plate? They should only be torqued to 9 ft/lbs which is not very tight. Tighten them in progressive steps in a cross pattern similar to installing lug nuts.

Do you have the service manual to follow?

 

Actually i torqued it down to 8ft/lbs. And yes when i torqued them down i did it in cross pattern... But the interesting thing is even if you screw down the bolts by hand just a little bit the pressure plate does not move at all... And i changed the clutch twice before and everything went good besides this time..

 

Why are you trying to move the pressure plate by hand? It takes the actuator engaging the lifter attached to the cable to move the pressure plate just enough to disengage the clutch.

Did you complete the install and see if the clutch worked with the bike running?

 

Yes i compleated installing the clutch but i did not start the bike yet because i am still waiting on some parts.... What happened was after i installed the cluth and adjusting it i put the bike in 2nd gear squeeazed the lever and tryed to move the bike and the cluth did not work.... The clutch lever feelth smooth and when i released the lever it snapped right back but the bike did not want to move.... So thats when i took it apart again and tryed to move it by hand

 

Did you install new clutch fiber plates? Otherwise you should not have needed to adjust the clutch cable. Do you feel tension when pulling in the clutch lever or is it too easy? How much play do you have between the clutch lever and the mounting bracket? Check the play where the lever itself rests against mounting bracket. I use with width of 2 nickels to set the play between the lever and the bracket. If there is too much play in the clutch cable it will not disengage the clutch when you pull in the lever.

 

Yes i installed new friction plates, new steel separator plates, new springs and bolts... And yes there is plenty of tension when i pull the lever and there is almost no play in the clutch cable. My grand father (a retaired car mechanic) told me that i should put it all back together and star the bike and then to see if the clutch works.... But i dont think it would make any difference if its not working with out starting the bike right now...

 

Why did you have the outer basket off the bike? Are you sure you got it back on correctly? Takes some pictures along the way and post them up here.

If you still have the cover off I would remove everything back to the judder spring and seat then re-install everything just to make sure its correct. The order is simple: judder seat, judder spring (outer lip facing out/like looking into a bowl), slim clutch fiber, then alternate steels (place the squared edge facing out towards pressure plate), fibers in the deep grooves until the last fiber (green edge) that goes in the shallow groove, lifter pin, pressure plate, springs then bolts.

If this is how you installed it then it should be fine once everything is back together and filled with oil as long as the outer basket is installed correctly.

 

I change crankshaft bearings along with second gear so the basket had to come off...And everything is put back together now just the clutch needs to be installed so it works and ill be good to go... judder spring and seat i did not touch them i left them in the inner part of the basket the whole time and when i installed the first friction flate (the smallest one) the judder spring fit inside of the friction plate with out a problem... just in case i am going to go to garage and take it all apart and put it back together and ill let u know if anything changed...

 

Ok here is the pic of the fiber plates... All of them are the same besides the last one( to the right) and all of the plates are labeled k3 a8 besides two second to last which are labeled k3 a7... So what i did i put the a7 fiber plates the last..... and still nothing got the same result as before...