Hi All,

Looking for a bit of advice and assistance, Ive just replaced the clutch plates on my xt660z and have put the cover back on making sure that the two notches on the clutch spring line up without the cable attached after numerous attempts.

The problem i have is theres no resistance in the clutch handle bar lever meaning i can engage the clutch by using little finger and the lever is wobbly! i didnt adjust the clutch cable at all to remove it so its not a case of readjustment but there doesnt seem to be any resistance from the clutch itself. ive had the clutch apart so many times now trying to figure it out but with no joy and no idea what the problem is.

Hoping someone can give me a clue.

Thanks Neil.

Usually this sort of trouble comes from the pull rod teeth not being either lined up, or engaged with the teeth on the release arm shaft. If not correctly aligned and with the teeth meshing the clutch will not disengage and there will be loads of slack at the handlebar lever.

Remove the cover. Rotate the pull rod so the teeth on the end are facing toward the rear of the bike. Fit the cover making sure the release arm is pointing rewards parallel to the side of the bike ( ignore the punch marks at this point). If the pull rod teeth and release arm teeth are meshing correctly you will notice the release arm move clockwise as the cover is slid into place.

Once fitted you can then push the release arm as far forward as it'll go with your finger and at that point the index marks on the casing and release arm should line up. If they don't then remove the cover and rotate the release arm shaft (not the pull rod) by how ever much short or over the index markings you are.

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Thanks Pleiades, I will give it another go.

cant believe how frustrating it is trying to get the rod arm and pull lever to line up properly as the manual makes it sound so simple and i must have been faffing about removing the clutch cover so many times now ive lost count. the spring arm did move forward as i replaced the clutch cover so thats why i doubted they werent properly aligned.

will let you know how i gete on and once again thanks for the help.

Neil.

You think you've got trouble - have a read of this guy's woes when trying to get the clutch changed and working properly - its an epic story! Reading it will make you feel a lot better and more positive about your predicament.

http://www.xt660.com/showthread.php?t=20931

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Update

Thanks once again Pleiades for the advice on the spring lever, I pulled the arm just past parallel and the clutch cover went on easier than it had done but when lining up the marks and trying to push it past seemed solid so connected the cable back and now works great.

Once again many thanks.