clutch problems (yeay)

[nastynate6695]

Hey everyone been gone for awhile.. hope nothing bad has happened since i last checked in...

Unfortuneately im forced to come back on not so great terms.   Instead of actually having time to enjoy the site (between work and school) i have to do a quick in and out..      my 96 gs  with a 92 motor was leaking oil on the right side case cover.  so i decided to change the seal ..  this caused a whole nother fiasco i dont have time to explain.  While the case was off i swapped my good clutch from the blown 96 motor in place for the slipping clutch of the 92.  Tonight i was able to put the whole bike back together and started her up.  When i went to put her into gear. nothing happened.  the bike is in permenant neutral.  What on earth did i do wrong or could be causing this problem.  I put the plates back on the same way i took them off..I loosened the clutch cable up thinking that i had it to tight and it was engaged,, but that wasnt it...
so any advice would be great.  I m not looking forward to ripping back into the engine and wasting all that new oil ...but what other coice do i have...??

[Danny500]

Hah, i originally thought cable.. but I didn't read that last sentence.. lol. 

Um, the only thing I could think it would be would be the bolt/nut holding the cage to the shaft. You may be spinning... I'm not sure, but there may be a woodruff key in there that you forgot to install?

I dunno, I'm sure Buddha will be along.

Dan

[the mole]

It's not in neutral, the gearbox works but the clutch won't transmit the drive because you made a little mistake in reassembly, you need to pull it apart to find out what. After you fix it, check its working (turning it over on the starter with the plugs out) before you reinstall the cover and oil. If you clean carefully around the drain plug and use a clean container, you could re-use that new oil.
If it makes you feel any better, a friend and I swapped the motor in his car one night, it started and ran just fine so we had a few beers. When we tried to drive it out of the garage it was like your bike......we looked around and found the clutch plate sitting on the bench ready to be fitted!

[nastynate6695]

I took a look in the manual but it doesnt list any problems that might occur.. The only thing i can think of is the compression pin is stuck.  Hopefully on wed i will be able to take it apart and mess with it this time i wont put the cover back in place until it functions properly.

[nastynate6695]

ok so i found out where i screwed up at..

apparently when i swapped one clutch for the other the needle bearings stuck to it.   But didnt stick to the one on the bike so i ended up with two sets of needle bearings  on one clutch.