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Message started by Reesetricted on 06/29/20 at 20:31:14

Title: Clutch lever not working....
Post by Reesetricted on 06/29/20 at 20:31:14

I've found a couple threads citing something similar but, haven't seen a conclusive resolution and can't find anything that answers all my questions so... I post.

Situation:. Hadn't ridden the bike in a while. Bike worked fine last I rode it. Got on to fire up and freshen it up but, when I grabbed the clutch during my unconscious start up ritual, it was flaccid. Zero tension. It basically went to the handle with no effort and didn't return when released.

My thoughts and questions: Looking at the release arm, and knowing the cable wasn't near stretched when last I rode, I assumed it was a return prong on the release arm. Today, I pulled the clutch side cover to check the spring. The crank case was FULL of gas\oil mix. I turned my petcock off so, that sucks... Leaky petcock. The spring looked normal but, not knowing exactly what it looks like, I'm not 100% it's intact and not 100% that it isn't worn out. However, like the cable, it was just fine the last time I rode so, insta-wear seems unlikely. I've seen posts about the throwout bearing being a culprit in situations like this.

1) how do I test the throwout bearing? (I cannot push the push rod which extends .5-.75" from the middle of the clutch basket)

2) now knowing my oil was just fuel, I wonder if it wasn't returning due to friction. The spring definitely has some recoil to it when I was messing with it, with the case off. Perhaps both cable\sheath and release arm friction?

3) having already taken every thing apart, this is going to be difficult without a pic so.... Sorry for this. Is the spring 2 ended? The shorter bent end situated between the notches in the cover and the longer end braced about the push rod actuator?

If I can somehow rule out the throwout bearing, I guess I just reassemble, adjust the cable and.... Hope. 99% it's in neutral so, that's good. Any input is welcomed.

Title: Re: Clutch lever not working....
Post by Dave on 06/30/20 at 03:06:04

There are 4 springs inside the clutch that give it tension....you did not break all 4 simultaneously.

Look inside the clutch cover. The throughout lever is made of sintered metal and sometimes breaks....and creates a flacid lever and the inability to get the clutch to release.

Title: Re: Clutch lever not working....
Post by Reesetricted on 06/30/20 at 06:48:02

When you say "throughout lever", do you mean the "release arm" in this diagram? If so, it appears to be ok, comparing to others I see online. To be clear, there is no throwout bearing, the clutch springs work in that capacity? Seeing the diagram, it appears so.

42797463727E656378707D62110 wrote:

Title: Re: Clutch lever not working....
Post by justin_o_guy2 on 06/30/20 at 08:18:12

Title: Re: Clutch lever not working....
Post by Dave on 06/30/20 at 14:06:33

I meant to type "throwout" lever.....not sure if spell check changed it or I was just absent minded.

JOG posted the correct part #5.......they call it a release cam.

Title: Re: Clutch lever not working....
Post by justin_o_guy2 on 06/30/20 at 14:25:08

Jog runs in a circle in the shop
Patting himself on the back,, then, cautiously reaches in
The Drawer on the toolbox,,
And retrieves the paper with the'Gold Stars on it,, and puts one carefully,, lovingly,, on his scoreboard,,

Noting,, sadly its the Only One

Title: Re: Clutch lever not working....
Post by Reesetricted on 06/30/20 at 19:53:43

No, worries. I wasn't trying to call you out on your spelling, just wanted to clarify.

Regarding the release cam, I think it is ok but, I'm going to post some pics of the potentially offending parts.

Title: Re: Clutch lever not working....
Post by Reesetricted on 07/01/20 at 16:44:55

Side a

Title: Re: Clutch lever not working....
Post by Reesetricted on 07/01/20 at 16:45:17

Side b

Title: Re: Clutch lever not working....
Post by Reesetricted on 07/01/20 at 16:45:45

Release arm side a

Title: Re: Clutch lever not working....
Post by Reesetricted on 07/01/20 at 16:46:18

Release arm side b

All look normal, don't they?

Title: Re: Clutch lever not working....
Post by Reesetricted on 07/01/20 at 16:46:47

Forgot to add the pic

Title: Re: Clutch lever not working....
Post by Dave on 07/02/20 at 12:39:18

They look normal to me.

Title: Re: Clutch lever not working....
Post by Reesetricted on 07/02/20 at 12:54:36

Thank you, sir. I'll lube, reassemble, and report back.

Title: Re: Clutch lever not working....
Post by justin_o_guy2 on 07/02/20 at 13:15:08

That Oring the rod passes thru is almost a dmes worth of rubber.
They do leak sometimes
Its not a big deal if it oozes,, but fixing it means a trip back in,,
Ya might be ahead to just put a fresh one in,,

Title: Re: Clutch lever not working....
Post by Reesetricted on 07/02/20 at 13:21:06

I appreciate the advice. I'll replace it.

Title: Re: Clutch lever not working....
Post by justin_o_guy2 on 07/02/20 at 14:36:14

Dont forget to oil the shaft and Oring, and make sure there are no burs on the shaft,
We all know a bur on the shaft causes irritation,,

Title: Re: Clutch lever not working....
Post by Reesetricted on 08/11/20 at 00:59:52

Just wanted to follow up for the next guy. I restored recoil in my clutch lever. I'm not sure which thing did it but, I'm leaning toward the gas having removed any lubrication on the shaft and the resistance of the shaft against the case was too much to overcome. So. In additional to fresh oil, I also oiled the cable quite a bit. I didn't remove it from the bike but, I dropped it into the line for a while. It never dropped out of the bottom, likely due to bends, but, it def moves smoother. Was probably a combination of the 2 but, in messing with the shaft\case I can confirm there was enough resistance to overcome the return spring.

As a reward for the effort, here is a pic of my bike.

Title: Re: Clutch lever not working....
Post by justin_o_guy2 on 08/11/20 at 09:55:47

If ever in doubt, grab the arm the cable is pulling. If you can move it freely, stuffs busted.

Title: Re: Clutch lever not working....
Post by eau de sauvage on 08/12/20 at 18:09:06

I will add that, that part number 5, which is the sintered metal referred to earlier, is worthwhile buying as a spare part to keep in your toolbox, because if that snaps as my one did for no apparent reason, it may not be in stock and will have to come from Japan, as my one did. If it does snap then you get to practice clutchless shifting.