clutch won't budge

[CrazyCloud]

I put a new clutch lever on my 1978 gs 750, while adjusting free play there was a distinct POP as I pulled the lever in. I assumed it was the cable that busted, but I took the cable off and checked it and it is fine, so I reinstalled cable and now I can't pull the lever in at all at with the specified free play at the lever. I tried a spare cable with the same result. I took the clutch cover off (right side) and the lever is not disengaging the clutch at all. Cable moves actuator arm fine unti I get the free play adjusted so that it should be pushing on the plates.

I recently took apart the "clutch release" mechanism to clean it, but I don't think that's something I could mess up. Seemed pretty simple. I have adjusted the actuator screw several times. Any ideas on what to try next? I'm thinking I'll have to split the cases to investigate further?

[JEEPRUSTY]

revisit the clutch release mechanism

[CrazyCloud]

I had taken apart the outer 3 parts, cleaned and greased them. That all looks okay. Do the oil seals pry out with a screwdriver? The pushrod does not want to pull out from the left side, with sprocket cover and oil seal keeper removed. It pulls out about 1/2" and stops.

[CrazyCloud]

I left the seals alone and pulled the push rod from the right side. Seemed fine, just a bit of rust to clean off. Will be filing chatter marks off clutch basket before putting back together to try again.

[CrazyCloud]

So apparently the clutch release mechanism isn't meant to be slathered in grease. I cleaned it off and it's working fine now.

[matt1100]

Seems like you probably had something bound when you replaced the cover. Like the gear on the release shaft didn't engage its mate. It wasn't the grease, but glad you got it working again