Clutch moves but doesn't work

Hi guys. Long story short I changed my clutch cable only to put the old one back on. However, no the little lever down on the motor moves like normal, but the clutch doesnt work. Also, it doesnt have enough force to pulle back and return to its normal position. Could it have become disconected inside somehow?

 

Nope. It's trapped and can't really disengage. But it might have got spun around or jumped teeth and needs to be re-oriented.

There is a little 'pip' on the case and a mark in the "butt" of the little lever. When the lever is pushed forward (in the direction the cable pulls it) by hand, it should stop with those marks aligned.

If it doesn't, then remove the clip and back the lever up a couple of splines until it stops with the marks aligned. Then re-attach the cable and adjust.

The "starting point" for the cable pulling the throwout lever is when the lever stops when being pushed by hand; those little marks need to be lined up at that point.

If that's not it then possibly there is something wrong inside. But if it worked beforehand, I suspect it's just throwout lever positioning is all.

 

Ok I'll take a look at that. Thank you sir.

 

First, ... Rotate the Free-play out of the Clutch ROD extending down into the Case.

Wrap a Shoelace around the ROD -- ( Like a Pull Starter ) -- Pull-out the Slack.
Tape it to the Case while you Adjust the Cable and Throw-out ARM.

Minimum Throw:
Illustrated in accompanying photo.

 

make sure you have the bolt in the lever that sits on the pole into the clutch, no bolt and it will slip and jump, if not back it like they said

 

There is no "bolt" in/on the throwout lever. It is held onto the shaft by a c-clip.

 

Not sure if that's the problem. I can move it up till it stops by hand and it still doesn't work.

 

OK. Move it until it stops by hand. THEN attach/adjust the cable so that the "stops by hand" position is the starting position for the cable pulling on it.

 

Ok, I see what you are saying, and excuse my ignorance, but if it wont go further by hand how will it move with the cable?

 

Because your hand does not have enough "mechanical advantage" at the stubby little lever to lift the pressure plate off the pack against the springs. Even with a pair of pliers, it is nearly impossible.

The lever/cable DOES have the necessary mechanical advantage.

 

this is more or less an issue of trial and error...put the lever on, if bike doesnt move, adjust lever 1 tooth forward, and so on till bike moves. you are supposed to line up the marks, then adjust the nuts where the cable is bracketed on. may need to adjust the clutch hand lever as well.

 

http://m.youtube.com/watch?v=WtpjD4tu6v ... re=related

 

Running into the same issue...I understand what I need to do to fix it, but I can't figure out how to reposition the throwout lever. Can someone explain it in more detail?

 

http://xjbikes.com/forums/threads/c...-cable-replacement-procedure.2672/#post-21621

Haapala, have you read this? Also please put your bike in your signature line

 

Thanks Luis! I had read that before but somehow missed what he was saying. All sorted out now.

 

good to hear!!