Clicking when spin wheel

[koolaid_kid]

O.K., your clutch cable goes into the left side of the engine cases as you sit on the bike. It connects to a worm mechanism which converts up and down motion into side to side motion. You have messed it up somehow, it happens. While you are fixing this, I strongly suggest that you clean and re-lube it. Instructions follow.
First, remove your footpeg and shift lever. Now remove the sprocket cover. You called it something else, but it is a sprocket cover. Disconnect the cable. Now, in the sprocket cover you will see two phillips screws holding the mechanism onto the sprocket cover. Remove those. If you have and impact screwdriver this is an ideal time to use it. Now pull out the worm mechanism and take it apart (it unscrews). It is most likely all gunked up. Clean it very thoroughly and re-grease it. Marine grease is best; available everywhere.
Put it back together and re-install it, making sure that the part the cable slips into is vertical. Tighten it down. At this point, you really should lube your clutch cable. It is an ideal time and you will not have to do it again for a while. Disconnect it at the handlebars and drip some oil down it or spray some lube down it. Make sure it slides freely.
Pull the clutch rod out (the part sticking out of the transmission and check it for straightness. Roll it on a smooth surface (glass is best) and look for bumps, rolling sideways, anything that does not look right. If it checks out, re-insert it into the transmission.
Now, you are ready to re-assemble. Here is where you messed up. The clutch pushrod slips into the center of the worm assembly. You most likely missed the center. Slide the sprocket cover onto the shifter shaft and toward the engine cases. Bolt her up, adjust it, install the shifter and the footpeg and you should be GTG.

[glenwill]

Thanks for your replies. I took a video of the worm mechanism. It seems to be functioning ok.

https://plus.google.com/u/0/10331580...ts/JyafM7A6K9f

I'll take it apart and clean as you suggest anyway, and I already have marine grease. However, it does look like it is working. It rotates, and when you look at it from the side, you can see it move in and out as it turns.

I have been able to adjust the various adjustments so that the clutch slips, but not to where it releases. When I try to go further to get it to fully release, it starts slipping even when the clutch lever is released.

I opened the oil fill cap, and shined a light in while pulling the clutch lever, and I do see the clutch plate move out.

The clutch was working fine until I pulled the sprocket cover off. Unfortunately, the instructions I had for the sprocket cover removal said to loosen the clutch adjustment screw first, so I may have just gotten it completely out of adjustment.

I just can't figure out what I am doing wrong.

[glenwill]

Also, the pushrod does not pull all the way out. Should it? It gets stuck after pulling out maybe 3-4 inches.

[koolaid_kid]

Yes, it pulls out. If you loosened the screw then perhaps you are just out of adjustment. There should be a procedure in your service manual.

[glenwill]

My pushrod does not pull out. It doesn't jam and get tight, it hits a dead stop. Here's a quick video:

https://plus.google.com/u/0/10331580...ts/7ZFoKxWWmNv

It seems to be the design of this model, or something is wrong inside the clutch, which I have not touched.

I cleaned the worm gear, greased and reassembled. Same result.

The most adjustment I can get by adjusting either the screw shaft on the front of the cover or the screw nipple that goes in the top of the cover is to get a small slippage of the rear wheel when the clutch is pulled. This requires me to push hard to get it to just barely slide. When I release the clutch, it stops.

If I attempt to adjust further so that the clutch will release, it never does, but it gets to where I have the very limited slip even with the clutch lever released.

I have followed the Clymer manual instructions 5 or 6 times and have the same result.

I am at a loss. Looking now in the OEM manual linked on this website to see what it says.

[glenwill]

Regarding the adjustment, it would seem to me that the push rod mechanism is simply that as it is pushed in a little the clutch starts to slip, and if it is pushed in further it fully opens the clutch.

If I get it adjusted so that it starts to slip, continuing to adjust it should fully release the clutch.

There is either something wrong with the clutch (which has worked fine since I started fixing up the bike), or I am misunderstanding something.

Glen

[hampshirehog]

The pushrod has got a scrolled end and won't come out from that side.

[glenwill]

Thanks All. I think it is just that I'm still a noob, and am struggling to know when the clutch is adjusted properly, and how to adjust it properly.

If I have the motor off, clutch released and the car in 1st gear, should I be able to push the bike at all? I.E. strong resistance, but some movement? Or no movement at all?

When the bike is in 1st gear, engine off, and I pull the clutch in, should there be any resistance to me rolling the bike? I.E. should it be just as easy to push as in neutral?

I cannot seem to get an adjustment that does not move at all in 1st with the clutch released, but rolls without resistance when the clutch is pulled in.

[hampshirehog]

If you have the bike in gear and the clutch pulled in you should be able to roll it. It might have slightly more resistance than when in neutral but not much.

If the bike has stood there's a strong chance that the plates have got stuck together. If this is what has happend then run the bike till it warms up - the oil will get thinner and the plates will usually release easily.

[glenwill]

Thanks for your help. I think I finally got it adjusted ok. Might need to tweak again, but I took it for a ride, and it felt good. No slippage that I noticed, and shifted fine.

Sooooo.....now that that annoying diversion is out of the way, this is a picture of my front sprocket:

https://plus.google.com/u/0/10331580...ts/EZwgF5SMnLL

How bad does that look? I suspect I should go ahead and replace the chain and sprockets, but with a number of things the bike needs done, I want to prioritize where my $$ goes.

Glen

[hampshirehog]

It's always harder to tell just looking at the fronts but that sprocket does look hooked. Try adjusting the chain - if you get a tight spot or a sloppy spot that's a definitive.

[glenwill]

Other forums I am a member of (computer tech, mostly) have a thanks button you can press to show your appreciation.

If GS had one, I'd press it over and over for you guys.

Thanks so much for your help with this.

Tomorrow I finish my BRC, will (hopefully) get my license, and I'm getting comfortable being out on the road. Loving this motorcycle world! I'm hooked.