Hi guys. I finally got the 1986 back together after starter gear failure.
. The clutch basket was removed and all disks cleaned, the engine was flushed twice before firing up with new oil.

Now when I go to shift I get a grind so the clutch isn't disengaging. It shifts fine when the bike isnt running obviously.

I followed the manual when putting everything back together and removed any Freeplay in the clutch lever on the case.

I torqued the spring bolts to spec. Are they meant to still have any spring range left or are they meant to bolt all the way down and then torque like I did ?

It was shifting great before I pulled it down.

I torqued the springs down to spec and made sure to slide the pushrod in . Is it meant to be pushed in with any force ?

I'll be pulling it back apart to check tomorrow. The other thing I thought is that maybe because it was cleaned very well it isn't coated in oil yet, not sure if that will make a difference

Ill check the lever now. I adjusted it to be tighter.

I mentioned it shifting when not running just to clarify that the linkages and everything are working fine so it is a clutch issue.

I mixed up some of the clutch plates when cleaning them. Is there a particular plate that needs to go first?

Moarpower wrote on 10/05/22 at 14:59:25:


there's only 1 plate that's different and that goes on last.

In the middle.

It was also grinding before I tightened it. At that point it was sitting lower.

I just realized there is on larger diameter friction disk. There is a chance this was not installed at the start of the stack. As a matter of fact Im not sure there was actually a larger one in the stack. I'll pull it apart and check but I believe they were all the same size.

I pulled it all apart, made sure the bigger disk was just after the large spring washers, reinstalled it all and still getting the same grinding, what's worse is the large locking bolt stripped when torquing it down, I flipped it over and was able to lock it into place but now Ill need one of those too.
I have not yet changed the pads and steel plates but I have ordered them along with new thrust washers and springs.

There is no movement in the clutch plates when it's torqued down and the clutch lever is firm.

IM really at loss here

Moarpower wrote on 10/05/22 at 17:44:40:

I'd like it better if that wasn't true.
Why would you Say that JoG?
Well, because it sounds like the clutch basket and all of its bits and pieces are disengaged completely.
So what is allowing the rotation of the crankshaft to continue to spin the input to the transmission If the clutch is disengaged?
What oil are you running?
I very often just don't Use the clutch from second on up and back down, the clutch, because of the big jump in gear ratios between first and second, is used there.
Have you tried making the change Quickly, just as soon as the lever is back a quarter inch, slap the gas shut and grab a gear?
Have you checked to see how far you have to pull the lever, engine off,in first gear, light pressure on the bars,trying to roll it, how far does the lever have to be pulled to disengage the clutch?


As a former warehouse manager I learned that when ordering stuff the question isn't
How much is this part?
It's
What is the Price And Availability?
It's pretty crappy of people to not tell you they don't have it in stock, but most people will sell it to you and then try to get it to ship it to you.
I've even had them lie to me. I've been buying things for a customer who Needs the product, make a few calls, someone quote me a price and tell me I should have it in three days. So I would tell my customer we otta have it in three days. I got chewed out several times before I figured out what was happening and stopped giving my customer a date. Unless it was someone I did a lot of business with and trusted them to tell me the truth about when I would get it.

Sorry for the noob question but how do I know which size pins i need ?  Or do I just try them all

Moarpower wrote on 10/08/22 at 16:25:55:

I pick the one that sticks out of the pack about 12 to 12.5mm