erratic clutch engagement (fixed!)

[dropitlow88]

Ok, old problems solved, new problems surface. When riding normally, just cruising through town clutch actuation is great, has good feel and good throw. After revving the bike to about 10k speed shifting properly, the clutch acts like a failed hydraulic unit which makes no sense to me. It won't disengage until I slowly shift down through the gears, find neutral while still rolling, and sit there and mess with it for a few on the side of the road. Highly annoying and potentially dangerous. Any ideas? I'm stumped..

[Kijona]

My guess is that it's overheating and the plates are sticking together. Try changing the oil? 

[Kijona]

Or, maybe...the actuator needs some lube. Could be that the excessive heat is causing the metal to bind up.

[dropitlow88]

The oil is brand new castro semi syn 10w-40. When it acts up the clutch lever has no resistance to it. Cable is ok and lubed as is the actuator, I checked over everything when I reassembled the engine less than 200 miles ago

[slipperymongoose]

Re adjust your clutch adjuster nut on your front sprocket cover.

[dropitlow88]

That could cause random disengagement issues? Interesting. I'll try and report back. Could you explain your theory to me?

[slipperymongoose]

Well it's a good place to start, check over everything to do with the clutch before going internal.

[dropitlow88]

I'll double check it but when I reassembled the motor I adjusted it snug then backed off slightly and locked it down. It releases about half way normally, when its working properly. When not working properly it goes all the way in with no resistance, no disengage.

[slipperymongoose]

Yeah check it again and then re do yor freeplay on your lever, if its still no good then something is going on within.

[oz353]

The oil is brand new Castrol semi syn 10w-40. When it acts up the clutch lever has no resistance to it. Cable is OK and lubed as is the actuator, I checked over everything when I reassembled the engine less than 200 miles ago

can you show us a pic of the front and back of the oil bottle you used?
beeing a lurker here Ive read quite a few times that synthetics can mess with the clutch. I'm wondering if you have used an oil with friction modifiers in it.
have you watched baltimoregs and adfalchius's videos?  (sorry if i misspelled that) in the beginning of their oil change video they cover what you should be looking for when you purchase oil.

then again I'm speaking with only what Ive read here. i dont even have a rideable bike yet.

[dropitlow88]

Ive read about oils and usually friction modifiers are in the lower weight oils, and they cause issues with slippage. So far no problems with slippage.

[Funderb]

the problem will probably be in the clutch adjustment on the engine, try that first, it sounds like your too tight.

manual says:
loosen cables
remove small cover
loosen lock nut
loosen set screw 2-3 turns
tighten until high resistance
loosen 1/4-1/2 turn

Adjust cable tensioners as needed.

Cover screws are easy to strip, be careful.

[dropitlow88]

this is what i used. api service sm. no friction modifiers. i actually think i may be too loose on the clutch. it dosnt slip at all, just sometimes will not disengage, im going to check over everthing really well tomorrow. i just got home from work..no time for anything tonight.

[dropitlow88]

ok, couldnt help but to go out and look at it. re adjusted everything, will try it out.. as soon as i fix another problem i just found, gas leaking into crankcase.... guess i gotta pull the carbs off again. what a pita.. that airbox was a nightmare!!

[Kijona]

ok, couldnt help but to go out and look at it. re adjusted everything, will try it out.. as soon as i fix another problem i just found, gas leaking into crankcase.... guess i gotta pull the carbs off again. what a pita.. that airbox was a nightmare!!

Easiest way to mount carbs/airbox is to insert the carbs into the airbox and mount it as a whole.

[dropitlow88]

Wow, wish I'd thought of that fighting to get that air box in... I'm half tempted to do a lunch box or pods so I don't have to deal with it. Hopefully it just needs float adjustment and cleaning of needle and seat.

[twinrat]

you guys do it the hard way when you refit your airbox .just remove the petcock let it hang down under the battery ,push carbs into inlet rubber boots then slide airbox at a slight angle between the frame and push over carb inlet ,making sure they are all the way home ,do up the two airbox bolts and tighten the hose clips on the front and rear of the carbs ,reinstall petcock with its capscrews .JOB DONE

[dropitlow88]

ok, got it going again, after few unseen problems. changed the gas soaked oil, cleaned the carbs again. filled it up full with gas since the first time i've owned it and the gas tank starts leaking... turns out previous owner tryed to repair pin holes using body filler..... so after riding home smelling like gas and dealing with a strange clutch i was getting really pissed lol. i pulled the tank off, and as a temp fix covered the holes with jb weld, sanded it then filled it in with bondo. we'll see how long it lasts. if it comes to it i will take it to my dad's house and weld it up. So... on to the clutch. Turn out when i re-assembled the motor i didn't get the splined section of the basket tight. and i didn.t bend over the lock washer.. so the clutch was slowly backing it's way off and had just begun to chew into the case ever so slightly. btw, i noticed it's trend after riding for about a half hour so i could better replicate its symptoms. the clutch cable was at full adjustment by the time i got home. I grabbed a few tools, tore it apart, and this time used my impact to insure a tight nut, then i bent the tab over, Guess that's what i get for throwing it together without a manual. On the plus side it's running beautifully now (for now  )

[slipperymongoose]

Glad to hear your back on the road

[dropitlow88]

Glad to hear your back on the road

Thanks! feels good to be back on the road. next on the task list is valve seals. It smokes alot on start-up. i like tinkering though. don't mind the work.