clutch wont disengage :/

[aaronmact]

hey mates! So im finishing up my project bike tonight and i went to roll it out of neutral ( holding the clutch lever in) and when I did it just plain stopped. This led me to finding the bolt that moves my pressure plate was placed on the outside of the plate instead of the inside. But now Ive buttoned everything back up the correct way (or what i believe it to be) and when i try the clutch it still doesn't work. And when I push on the little push rod actuator by the front sprocket I cant see the pressure plate move at all. Even when i have everything back on and try to use the lever and cable it wont work or disengage. Suggestions on what i might do? :/

[Soloratov]

I know the pushrod design is a relatively...well...crap design. Chances are you just missed getting it engaged properly when you put it back together. It's easy to miss, it's a delicate process of sliding everything together while you make sure it's lined up just right. You will have a hard time testing it without at least having the side cover on the bike, since moving that pushrod correctly without the cable and lever is, almost impossible. Check the assembly diagram again, and just double check yourself, I'm thinking that's all it is.

[adidasguy]

Please explain "and when I did it just plain stopped."

Did the bike lurch then die? Or did it just turn off?

There is a side stand switch - if the side stand is down and you put in gear the bike will turn off.

[aaronmact]

Well here's an update. The last guy to have the bike re assemble the clutch wrong and put the gold push rod on the outside of the pressure plate :p

[Soloratov]

Well that'll do it! 

[aaronmact]

Yeah, and supposedly the last one to own this bike worked in a "bike shop".  But ive pretty much got it sorted now. Will there be resistance on the back tire if i try to spin it when the clutch lever is pulled in? or should the back tire rotate as freely as when its in nuetral? I included some images of last night showing how I found the push rod and the damage the push rod caused. It was to the point it was coming out the other side of the cover, and also of the nasty ass motor oil I found in the bike.

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[Soloratov]

In a perfect world with the clutch adjusted it should spin nicely. Mine never has though, I have always had a bit more drag with the clutch than when in neutral...but I know things are slightly off on mine. If you spend the time adjusting all the points properly, you should get the same roll as neutral.

[aaronmact]

Alright, I figure the plates might be dirty from the oil and that might be adding a bit of resistance, or do you think if I actually run the bike things should free up? Because this bike hasn't run in 9 years

[adidasguy]

Cool - no wonder it wasn't run with the clutch being assembled wrong!

You can remove the clutch plates and clean them in kerosene. Then soak in new oil before reassembling. That will give you a very smooth running clutch.

Oh, and rotating the rear tire in gear with clutch pulled in: there will be a little resistance. Less resistance if:
1. clutch plates are clean
2. bike and oil is warm

Clutch plates get sticky and dirty. That's why the bike often jumps when first put in gear the first time when cold - plates are a little stuck together. There is very little space between them. any gunk will cause a little resistance.

[aaronmact]

alright thanks so much for all the help so far! Ill be sure to clean and soak the plates once I get back from meeting a guy for parts in Baltimore tomorrow! and when you say oil you mean regular motor oil I presume?