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Tranny/Shifting problem

DSC01486.jpg

Here is the linkage with the clutch assembly removed
 
Your clutch actuator arm needs to be repositioned back, it is in the position now it should be in after pulling in the clutch. Remove the bolt, pull it up and reposition it back a few splines, so it starts in 1 o'clock and finishes in 11 o'clock.
 
Make sure the the notch at the back of the clutch hub fits into the oil pump gear.
I have to agree. The clutch actuator arm is off.
 
If I understand this right, the arm on the left needs to be higher?Put that gear in the 1 o'clock position and the upper edge will finish it's stroke at the 11 o'clock position. Thanks.

Andy

P.S. I'm not trying to sound like an idiot, but I don't want to have to take it apart many more times.

Thanks for the info.
 
your shifter looks ok - if that pic is taken in neutral gear - so dont move it

what everybody is on about is the actuator arm in your first pic
if "12" o clock is when the arm is paralel with the engine (facing straight forward), you want it positioned at 1 oclock so when it is pulled in by the clutch cable it comes to 11 oclock
 
Adjust the arm so it looks like this...

Clutcharm.jpg
 
Last edited:
SqDL,

I noticed what you said,and tried it then as now and it still doesn't friggin' run in gear with the clutch depressed:mad:. I think the only option now is to replace the clutch cable. Probably should have done that to start with, but it appars to be in good shape. It does seem long, however. I'll either get one from a local shop or order one online(which ever is quicker) Will keep you all posted.Thanks.

Andy
 
I hope your lining up the splines on the release rack when you put the clutch cover on?
 
Last edited:
Sorry if this seems rudimentary but have a few comments and instructions that should get you back on the road.

When you showed the photo of the clutch arm it is too far inboard toward the bike. The clutch will not release properly with the arm in this position.

You need to a) remove the clutch cable from the arm and b) remove the screw and arm from the release lever.

After you have the arm off, install it in a position similar to mine, or even further outboard.

Install the cable back and adjust out the free play. The 850 clutch cable has a length adjustment in the center of the cable so you may need to play around with the length to get it right.

Is this clear?
 
The splines seem to be lined up when I replace the cover. It also seems like the cover would not go on if they wern't lined up. Or can it?

I did reposition the arm like yours. I also totally forgot about the adjustment in the middle of the cable. I will look at that in the morning and would be happy to find the problem there. I also ordered a new cable today. A $15 dollar pice of mind, if nothing else. Thanks again.

Andy
 
My cable is in, I'll pick it up in the morning. I removed the old one and there was no adjustment in the middle. Possibly the wrong cable? I'll know more after I get the new one.

Andy
 
OK guys, getting desprate now. Installed new clutch cable, looks good still have the same problem. I guess the pressure plate is not disengaging. Is it possible to assemble the clutch cover and not have the pinion gear and splines lined up? Is there a spring or something that goes into the clutch cover to put pressure on the throughout bearing shaft, the manual does not show one. I am almost certain the splines and shaft are lined up, when I acuate the pinion shaft, I can feel/hear the shaft moving. Totally stumped on this one. Help, please.

Andy

I am also pretty sure the problem is something simple, can't see the trees thru the woods type of thing:oops:
 
What does the clutch lever feel like when you pull the lever? Is there a small amount of freeplay when the lever if first pulled but after that you can feel the clutch disengage?
 
It feels like all freeplay. A little restance from the cable itself, really no more. It feels like the shaft is just sliding back and forth and not doing anything.
 
So how about taking the cable back off the small arm driving the release mechanism and moving the arm with your hand? As you rotate the clutch arm is there some point where you can eliminate the freeplay and start to feel like the clutch wants to start to disengage?
 
I can't seem to feel the clutch disengage at all. I have tried to do it manually to no avail. What is the range of motion for the arm/shaft? Mine only moves about 45 degrees, maybe less. I'm just guessing.
 
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