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XT660X & XT660R General Discussions General discussion related to XTX & XTR Only |
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Clutch wont disengage
Hi! i recently change to a "new" engine and i had to use my old clutch that was working fine on my old bike. When i mounted the new engine into the frame and got everything together i noticed that the clutch wont disengage, i can change gears freely even when the engine is runing (without using the clutch and standing still). When i pull the clutchleaver it moves but i get the feeling that im pulling something that dont want to move, its really really stiff and hard, nothing like a clutch should feel like. if i put the engine into gear while its turned of i can see the clutch spining around as i push the bike around with no problem. The clutchplates are also a bit lose when i mounted the whole clutch in place, i can move the top plate about 2-3mm in the clouchbasket sort of thing.
anyone had this problem before or know something that might help? / Marcus from Sweden |
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As for the clutch, as Pepsi suggests, nine times out of ten when this problem occurs it is the pull rod and release lever/shaft that are out of alignment, gears not meshed or set in the wrong position. What you have to remember is the teeth on the pull rod must face backwards before the cover is replaced and the release arm on the cover must be pointing to the back of the bike also (parallel to the casing). As you push the cover home the release arm will (or should) move round to its normal position. At this point, when the cover is bolted down hand-tight, push the release arm forward as far as it will go to check the index/punch marks on arm and casing line up. If not remove the cover, mover the release arm back or forward at touch corresponding to how far out the punch marks were. A lot of people (and we had one only last week) make the mistake of trying to line up the punch marks before replacing the cover which results in... a permanently engaged clutch! I know you say you fitted the release mechanism correctly, but just double check by removing the clutch cable and push the release arm forward with your finger until it can't move anymore. Do the punch marks line up? Does the release arm move forward at all? |
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i can start the bike then put it into firstgear, with both the clunking nature of puting the bike in first gear and the neutral light turning off. |
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No it isn't. There should be no movement or gaps between the plates. If there is the most likely cause is the pressure plate isn't engaged properly with the basket and as a result the pull rod won't do its job either. Did you remember the thrust washer before refitting anything else? Did you remember the anti-judder seat and spring, which must be fitted the right way round (marked 'outside'). Are the plate tabs correctly located in the correct slots marked with triangles on the basket? The first (innermost) friction plate fits into the deeper right-hand slot (looking when the slots are at the top) and the final friction plate goes in the shallow left-hand slot. |
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I will be checking it later this weak when i get time to have a look at it. |
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clutch, clutchbasket |
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