what the hell is wrong with my clutch !!!

dougon2wheels · Post by **dougon2wheels** » Sat Jul 18, 2009 1:11 am

i just can't figure out whats wrong with my clutch,its built exactly to the manual but the actuator arm seems to be in the wrong position,and there's almost no movement in it !
i've taken some pic's of how i've assembled it.....

note the position of the actuator arm....its too far forward and there's almost no movement

any suggestions welcome.......

edgar90 · Post by **edgar90** » Sat Jul 18, 2009 2:02 am

hi,please help us,i have the same problem,

pleeeeeeeeeeeeeeeeeeeeease help us. [-o<

cheers

the-elf · Post by **the-elf** » Sat Jul 18, 2009 2:48 am

The method of assembly looks right. Have you got the lever in the right position before you assembled it with the flat against the thrust bearing arm?

Does it actual work at all when its connected up? Did you ensure that the basket had engaged fully with both the crank and the gearbox gears? It normally takes a bit of spinning around to get the gears to line up and then for eveything to slip into place.

JanBros · Post by **JanBros** » Sat Jul 18, 2009 12:47 pm

I'm sure everything is in the right place, otherwise you can't fit the final circlips.

can you post a picture off the lever

dougon2wheels · Post by **dougon2wheels** » Sat Jul 18, 2009 5:43 pm

JanBros wrote:I'm sure everything is in the right place, otherwise you can't fit the final circlips.

can you post a picture off the lever

agreed,everything has to be right for the circlip to fit.
its almost like the entire clutch assembly is too far back,the arm has freeplay from the position its suppost to be to where it is !,will do a pic of the arm later,but its hardly worn !
thanks for the help so far.......

JanBros · Post by **JanBros** » Sat Jul 18, 2009 11:05 pm

ditch the gasket and use only sealant bond. it 'll bring the leve closer to the pushrod. you can even ditch the big right hand side cover gasket .

dougon2wheels · Post by **dougon2wheels** » Sun Jul 19, 2009 12:06 am

JanBros wrote:ditch the gasket and use only sealant bond. it 'll bring the leve closer to the pushrod. you can even ditch the big right hand side cover gasket .

now there's an idea,before i stripped the engine there certainly wasn't a gasket on the clutch cover,and i cant remember if there was one on the side casting either !!,i will go to the garage now and remove the clutch gasket and see if anything changes.........

dougon2wheels · Post by **dougon2wheels** » Sun Jul 19, 2009 1:38 pm

sorted........
removing the gasket made very little difference......so i thought the only place the problem could be was in the plate pack,so i stripped it down again and found that there are 5 standard cork plates and 1 that has a bigger id......this plate must go by the big spring washers,this allows the clutch pack to move propperly.....there's no mention of this different plate in the manual though !!!!

the parts list does state that the plates are different......should have looked at the parts list.....