Clutch Clutch issues

Snarfu

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Feb 24, 2012
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Hey guys, I'm in need of your expertise again...

I took my clutch cover off to change the stock lube (I hate that red ****..) and rotate the clutch to keep it from sticking out at that awkward angle. When I wiped off the lube, a small, cylindrical shaft came out the middle of the gear-- and it won't go back in! Any tricks?

Also, does anyone know of a good how to on rotating the clutch arm?

As always, any help is appreciated.
 
The clutch arm is splined to the clutch cam. You might have to remove the 3 bolts then take the cover off to get the cam out but it sounds like you are already at that point.

The pin should slide in easily after you put the ball inside. (both should be lubed up really well)

If you remove the nut from the top of the cam then you can pop the arm off of the splines. Re-instal the clutch arm perpendicular to the way the clutch cable points towards it. You can do that by installing that pin inside the gear's center shaft. then installing the cover and cam without the arm on it. Once that is installed you can see what angle works best for the arm and start working it onto the splines. The total pull of your clutch cable is not very far... Maybe 1/2 to 3/4 inch...

Hope that helps!
 
To clarify, there is a ball that goes in first before the pin in the shaft that holds the drive sprocket. It might not come out if there is enough of their red lube packed inside.

Have you gotten the pin to fit back into the shaft yet?
 
No, I've been too busy eating lasagna and playing with the dog. I will get motivated shortly and search for the ball.
 
The ball is in there, but the shaft will only go about 2/3 of the way in before it hits it. :-/
 
Clutch

Sometimes the Ball Bearing is stuck inside. You can use a light to check inside the hole to see if it's still there. Sometimes they just fall out, sometimes an act of God won't get it out. If it's still in there and won't come out, just put a big glob of grease on the end of the pin (and all around the pin) and ram it home. This is the point on which the clutch spins with some pressure on it so grease it WELL.
Also try to get grease on the clutch arm where it goes through the case and on the flat part where it hits the pin. It's not a great design so it needs all the help it can get.
Also, While you already have the grease out, Take the cover off the other side and you'll see the small crank gear going to the larger clutch gear. VERY CAREFULLY, dab a little grease on the gears ONLY. Not too much or you'll throw any excess grease on the clutch pads and thats not a good thing.
If you ride a lot check these every month and lube as needed. If not so much every two or three months should do it.
Keep The Shiney Side Up, Rubber Side Down.
Big Red.
 
Unfortunately ramming it home isn't working. I could try taking a rubber mallet to it, but that seems a bit extreme.
 
Clutch

Unfortunately ramming it home isn't working. I could try taking a rubber mallet to it, but that seems a bit extreme.
It don't go all the way in bro, just about 3/4 of it. It sticks out about 1/2 inch or so to hit the flat part of the clutch lever.
Big Red.
 
Yeah, the pin should stick out of the gear a little bit. As long as the cover still fits over the gear with the cam flat against the pin you are good to go.
 
Clutch Pin.

Yeah, the pin should stick out of the gear a little bit. As long as the cover still fits over the gear with the cam flat against the pin you are good to go.
The "Cam" he's talking about is the Clutch arm cam. Thats the flat spot at the bottom of the clutch arm. When it is pulled and it turns the arm the cam hits the pin and pushes it in, disengageing the clutch. Be sure to put a blob of grease on that flat part (cam) too. And Cali is right, As long as the pin is sticking out some and the cover still goes on it should be cool. You can adjust the clutch further from the other side. When you get to that adjustment we'll help with that also.
Big Red.
 
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