lurching in gear

I-man · Post by **I-man** » Sun Nov 08, 2009 4:23 pm

put the cover on, no luck. anything else?

davomoto · Post by **davomoto** » Sun Nov 08, 2009 5:18 pm

Iman, remove the right cover, 6 phillips head srcews, and the 3 stator cover screws, and the cover will slide right off. You'll want to clean everything inside there, especially the clutch thread, aluninum part that is in the side cover, and steel part that threads in. Regrease, make sure the correct size ball bearing is inside the steel threaded piece, pack that part with grease as well. Re-install cover, back adjusters at both ends of cable off all of the way, and adjust to remove most of the freeplay at lever with the large slotted aluminum clutch thread, you will need to loosen the 10mm bolt that holds it to the cover. Then make fine adjustments at cable. It will be hard to spin the rear wheel by hand with the clutch pulled in. Sit on the bike, put it in gear, pull in clutch, and it should roll with very minimal drag. Hope some of this helps!

davomoto

I-man · Post by **I-man** » Sun Nov 08, 2009 5:53 pm

thanks davemoto. I don't doubt that you know what your talking about, but how in the world do you not need to take the kickstart off? does the kickstart come off with the cover? that must be right, right? thanks again. i'll let everyone know how it goes

mike69 · Post by **mike69** » Sun Nov 08, 2009 7:36 pm

You don't have to mess with kick starter, It comes off along with cover.

I-man · Post by **I-man** » Sun Nov 08, 2009 8:57 pm

thanks for that mike, hopefully I can get to it this week. strike while the iron is hot, and all that.

e3steve · Post by **e3steve** » Mon Nov 09, 2009 12:30 am

I-man wrote:just read in bill silvers manual 'later five plate clutch plates featured friction material bonded to a metal backing' so I guess it's likely that the metal ones don't separate from the friction ones. interesting. anyone know the torque setting for the four bolts that hold the clutch in?

Tight. Just tight. Use a quarter-inch drive ratchet so as not to overtighten. They won't come undone because they're always under tension from the springs.

And yes, all plates should separate from the neighbouring one. The metal plates are 'keyed' on the inner circumference, the friction plates on the outer. All must be absolutely flat, so if you have to prise them apart, then check them for flatness on a piece of glass as D suggests.

I've put together a logical collage of the relevant clutch parts in the pic.

EDIT: clutch component picture added

I-man · Post by **I-man** » Mon Nov 09, 2009 8:38 pm

took the cover off. kickstarter comes off with cover, but then everyone but me knew that ; ) . lots of old goop and gunk, but everything seems to be there, including the ball bearing. it doesn't come out of the threaded metal piece, nor does it seem to spin. is this right? What now? anything else I should look at while I have it apart?