Clutch Problems

[Rick65Cat]

O.K. Guys,

I pulled the cover off again to make sure i had everything lined up properly.

Here are the pic's:

Clutch cover:


Clutch Release bar:


I made sure the release rod (#18 ) was situated so the teeth would line up with the teeth on part #24 inside the clutch cover.

I put the clutch cover back on, then the adjuster, removed the oil fill cap and pulled the clutch in, with a flashlight I can see the clutch being disengaged and it has plenty of movement.

when my friend removed the clutch fibers to measure them with vernier calipers, does it matter what order they go back in?

The manual doesn't say and no one i've spoken with around town can give me a definitive answer.

Any other ideas ?

Tommy

It doesn't make any difference when you are re-installing the fiber plates as to the order. Just be sure they alternate with the steel plates..steel fiber steel fiber etc.
I can't remember how many of each there is either. there IS a sequence...just dunno which goes on first, steel or fiber.

[gixerbike1]

order

Hey Rick,

Yeah, I followed the correct order, Fiber goes in first and is the last to go in as well.

Thanks.

Tommy

[Turtleface]

Hey Rick,

Yeah, I followed the correct order, Fiber goes in first and is the last to go in as well.

Thanks.

Tommy

First in is the steel, according to your part's fiche. First steel holds in the wave washer (#11) and the wave washer seat (#9), and is held in by that little piece of piano wire. (#10)

[paco13]

Ok just checking but you see good movement through the oil fill, Did you start it and try it? does it still no engage?
If you can see the plates seperating through the oil whole, and it still doesn't disengage, then you have something bound up. Shaft or bearing, maybe missing thrust washer.

[TheCafeKid]

Gixerbike, Please listen to me. Part number 25 on your fiche, the throwout arm, is what spins the shaft to disengage the clutch. If you dont have the throwout rotated far enough, the shaft will not disengage the clutch all the way. Its a wet system. Oil between the plates will still cause grab. The throwout is actually pretty far, so even if you see it move some, it may not be enough. Try moving the throwout arm a couple splines counter clockwise and see if it helps. If it doesnt, I will shut up, but you just cant put it together in the same place it came apart because new springs mean more resistance, which means the spot where it was before may not be enough "pull"..

[gixerbike1]

Throw out arm pic's

Hey CafeKid,

I'm all for listening to good info, heck at this point peeing on a spark plug was my next step

I was at a cookout this afternoon so i didn't have time to take pics and respond.

So, here are the pic's you requested.





and



One thing i did notice, The EBC springs i got from DK were about an inch longer than the stock springs i pulled out, could they have sent me the wrong springs ?

Tommy

[TheCafeKid]

an inch longer?? That seems a bit odd. I know that old sacked out springs will be SOME shorter than new, but that seems a bit much..dunno for sure though. One thing I would try first however is shifting that arm OUTBOARD a few splines...You'll have to let some cable adjustment out to do it, but it might be the problem. I have to admit that set up is slightly different from most of the other GSs, just in the way its put together, but USUALLY that arm is either in line with the clutch cover, or pointing out just a touch.. If you do that, when you pull the lever, the arm will pull the clutch out farther and SHOULD disengage..

[gixerbike1]

2 splines over it is

Okay CafeKid,

I'll give that a try tomorrow and see how it does.

Thanks,

Tommy

[blowerbike]

OMFG!!!
AN INCH???????????
ok more pics tomorrow of both springs.

[gixerbike1]

more Pic's a coming

Hey blowerbike,

I can do that, I've gotta pull it back down anyway.

I measured my stock springs last night and they were right at 36.5MM like the manual states they should be.

I'm starting to thing the fibers were the reason for the slippage and these EBC springs are just too much spring for this bike.

I'll take pic's of both with the ruler in the middle for reference.

Tommy