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General Category >> Rubber Side Down! >> Clutch arm has no tension.
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Message started by Josh Talley on 10/22/14 at 17:33:24

Title: Clutch arm has no tension.
Post by Josh Talley on 10/22/14 at 17:33:24

So here's my situation. I recently purchased a cheap 87 savage with the intention on buying a Ryca motors bobber kit. It was kind of a gamble knowing that it needs some work. I replaced the petcock and brake cover. The last thing it needed was a new clutch assembly which I replaced going step by step with the manual. I put the cover back on and now my clutch arm doesn't have hardly any spring to it. When I take the cover off it has tension but one I put it back on it has hardly any pull to it. I am a complete novice at this so any help would be greatfully appreciated.

Title: Re: Clutch arm has no tension.
Post by justin_o_guy2 on 10/22/14 at 19:32:16

If you grab the clutch lever on the engine,can you swing it by hand?

Title: Re: Clutch arm has no tension.
Post by Josh Talley on 10/22/14 at 19:47:24

Yes when I grab the clutch arm on engine I can move it up and down with little to no tension.

Title: Re: Clutch arm has no tension.
Post by verslagen1 on 10/22/14 at 19:53:36

Simple, you left the clutch rod out.
about an inch and a half, 1/4" in diameter.
goes in the center of the clutch.

Title: Re: Clutch arm has no tension.
Post by Josh Talley on 10/22/14 at 19:57:23

I'm pretty sure it's in but it could have fallen out without me knowing. I'll check first thing in the morning and let you know if that was it. Thanks for the help.

Title: Re: Clutch arm has no tension.
Post by Josh Talley on 10/22/14 at 20:14:33

I quickly ran out and checked to make sure that wasn't the problem and unfortunately it wasn't. The clutch rod is in.

Title: Re: Clutch arm has no tension.
Post by verslagen1 on 10/22/14 at 20:18:59

too bad.
obviously, it's something you did ;D
the clutch ain't easy to get right the 1st time.
something must of slipped out of place.
take it apart and put it back together.
keep trying till you get it right.
and ask if you're not sure.
pictures!

Title: Re: Clutch arm has no tension.
Post by justin_o_guy2 on 10/22/14 at 22:55:16

But it was hard to move while the clutch cover was off?

I'm wondering if you got the clutch throw out either in wrong or it's busted.

Title: Re: Clutch arm has no tension.
Post by Josh Talley on 10/23/14 at 06:50:44

While the cover is off it moves just fine but as soon as I put it back on it just doesn't move right.

Title: Re: Clutch arm has no tension.
Post by justin_o_guy2 on 10/23/14 at 07:23:48

Well,, Youve gotta pop the side off and take pics of the clutch pack and thro out and rod and lets all have a look,, cuz you built yerself a bear trap..

Title: Re: Clutch arm has no tension.
Post by Josh Talley on 10/23/14 at 07:26:59

Haha will do

Title: Re: Clutch arm has no tension.
Post by Josh Talley on 10/23/14 at 08:33:11

Photo 1

Title: Re: Clutch arm has no tension.
Post by Josh Talley on 10/23/14 at 08:33:46

Title: Re: Clutch arm has no tension.
Post by Josh Talley on 10/23/14 at 08:34:40

Title: Re: Clutch arm has no tension.
Post by Josh Talley on 10/23/14 at 08:35:25

Title: Re: Clutch arm has no tension.
Post by bobert_FSO on 10/23/14 at 08:46:07

Just thinking, here.

Is it possible that the free movement you see is just slack in the clutch arm and the end of free travel is when the all the slack is taken out and the work of disengaging the clutch starts?

I don't think you can disengage the clutch by pushing on the clutch arm by hand. It's too stiff.

Have you hooked up the clutch cable, adjusted it correctly and then tried to pull the clutch in with the handlebar lever?

Title: Re: Clutch arm has no tension.
Post by Dave on 10/23/14 at 08:54:15

bobert might be onto something.

When the cover is on....and you gently push the lever up there will be some movement. The clutch lever should stop somewhere between the two marks cast into the engine block. At that point you will need to put a wrench on the lever to allow you to move the clutch lever against the force of the springs. When you gently push the lever up....it should be between these 2 marks.

Title: Re: Clutch arm has no tension.
Post by Josh Talley on 10/23/14 at 09:09:25

You guys are exactly right. You can see my inexperience with this. The only problem I'm seeing now is adjusting the cable correctly. Seems as if I have to have the cable tensioned all the way but I'll keep messing with it. Thanks guys I really appreciate the help.

Title: Re: Clutch arm has no tension.
Post by Dave on 10/23/14 at 10:49:31

Adjusting the cable is not a problem. Install the cable, and move the adjuster at the handlebars a few turns form being all the way in.....to allow yourself some room for adjustment at the handlebars. Then move the adjustment nuts on the bottom of the cable to provide just a small amount of movement at the lever.....a little slack in the cable so that all of the spring pressure of the clutch is working on the clutch plates...and not the cable. You want to be able to see just a small amount of movement at the clutch lever before you feel the pull on the clutch springs engage.

Also remember.....both adjusting nuts on the bottom of the cable are on top of the bracket. Do not put one on top and one on the bottom - some have made that mistake and broken the engine case.....that is a really bad thing.

Don't pay any attention to the red arrow in this photo....it was the only photo of the clutch cable I could find.

Title: Re: Clutch arm has no tension.
Post by Serowbot on 10/23/14 at 11:28:18

Ah see,.. now all I can see is that giant red arrow... :o...

;D ;D ;D...

Title: Re: Clutch arm has no tension.
Post by Josh Talley on 10/23/14 at 12:10:00

Thanks for that. The guy that ran the cable had the two nuts separated just like you said so I'll go fix that. Thanks again.

Title: Re: Clutch arm has no tension.
Post by Dane Allen on 10/23/14 at 12:55:33

Congrats on a successful first-time clutch repack!!

Title: Re: Clutch arm has no tension.
Post by justin_o_guy2 on 10/24/14 at 09:58:04

Im VERY pleased that someone came up with the answer,,, I apologize for adding confusion,,