So having rebuilt my 04FK, I have two major issues.
1. My neutral switch doesn't work so I have to zip tie the kick stand switch in order to idle the bike and i have no indicator to know when i'm in neutral. The contacts and the switch itself are clean and it did work before the rebuild. Once electrical mod I've done is the LED diode mod for the turn signals along with a new flasher relay. The bike is using all LED lights. Any thoughts?
2. My clutch does not disengage in the sense that power is not relieved from the transmission when the lever is pulled in. I DO have resistance, and you can see that the clutch has 1/2 inch when the lever is pulled in. So we KNOW that there is a disengaging movement, but there is no actual effect. The clutch basket is in good shape. The clutch fibers are new (soaked before installing), I've tried adjusting the clutch in all 3 places, I've zip tied the lever to the bar overnight and during idle. I've tried holding the clutch in while gassing it in 1st gear while on the rear brake (to maybe free up sticky plates). While riding and holding in the clutch there is no slipping or anything. It's as if there were no clutch at all. I'm kinda at a loss with this one. ANY ideas are appreciated.
EDIT: never mind, didnt read properly lol.
Not sure what to tell you besides check to make sure there are no shorts in your wiring harness and make sure all wires are plugged in properly. As for the clutch, have you verified that the clutch cable itself is intact?
Quote from: gearhead1994 on May 21, 2017, 04:10:19 PM
So having rebuilt my 04FK, I have two major issues.
1. My neutral switch doesn't work so I have to zip tie the kick stand switch in order to idle the bike and i have no indicator to know when i'm in neutral. The contacts and the switch itself are clean and it did work before the rebuild. Once electrical mod I've done is the LED diode mod for the turn signals along with a new flasher relay. The bike is using all LED lights. Any thoughts?
2. My clutch does not disengage in the sense that power is not relieved from the transmission when the lever is pulled in. I DO have resistance, and you can see that the clutch has 1/2 inch when the lever is pulled in. So we KNOW that there is a disengaging movement, but there is no actual effect. The clutch basket is in good shape. The clutch fibers are new (soaked before installing), I've tried adjusting the clutch in all 3 places, I've zip tied the lever to the bar overnight and during idle. I've tried holding the clutch in while gassing it in 1st gear while on the rear brake (to maybe free up sticky plates). While riding and holding in the clutch there is no slipping or anything. It's as if there were no clutch at all. I'm kinda at a loss with this one. ANY ideas are appreciated.
The neutral switch has that spinning multi position bobbin inside the countershaft cover. Does that move and spin when you shift it ???
Clutch basket engages to alternate fiber plates with those end tabs and its driven by the crank gear, and the hub engages to the steel plates with teeth on the inside.
Pulling the lever in takes off the preload and lets the outer ones spin without dragging the inner along.
Your case may be where there is too much pressure between a few plates and its still dragging.
See if your springs are on too tight or if the push rod is got some issues etc etc.
Cool.
Buddha.
I am an old Yamaha SR500 rider and former motorcycle mechanic (1964-1986), so all I can contribute is ancient history about general problems. I recommend taking the pressure plate and all the clutch plates out. Then try to see if the clutch hub turns free from the basket. If it doesn't, take the clutch nut off and see if things free up. My experience has shown that a misplaced shim or parts that are not aligned properly will cause this problem.