clutch....

[trbig]

It would take more than half a turn, but if you loosen that screw (The one you turned counter-clockwise) too much, there are 3 little ball bearings in that throwout assembly that can become dislodged from their seats and won't let the clutch retract. If this is the case, you'll have to pull that cover to get it fixed.. and while you're in there, might as well throw some new springs in. I can't tell you how many of these engines I've torn apart and in the past. I was harder on these bikes/clutches than anyone I've heard of, and I've only ever found one single clutch disc out of spec. Others have found some, but it's an extremely rare find to see one out. For some reason, I've kept probably a half dozen clutch packs worth of discs if you find you need one or more. They're used, but in spec.

[TopCatGr58]

Hey Jeff,

It does sound like you might have a little corrosion or old grease in your clutch cable, taking it loose and getting it lubricated will help both in allowing it to return, but also easier to pull. Also, does your lever still have the little return expansion spring that connects to the end of the throwout lever and the inside of the clutch cover case? Usually the pressure of the clutch basket and springs are enough to push/rotate the lever back up, but if there's some cable drag it can prevent it from returning back up.

Yes, the 3 little bearing balls CAN fall out but I've taken apart a few clutches also, and have found that sometimes the balls WILL stay in position even if the lever is rotated around too far. There are little crimps on the bracket that holds the balls, and can keep them in place, but sometimes they've gotten bent/loosened and then the balls can fall out of the bracket.

So...hopefully it's just adjusted too loose and some cable drag. If it's adjusted too loose, then it won't fully disengage the engine from the tranny and that can prevent you being able to shift it into gear or out of gear if you don't have the engine and wheels running to have them close to synched.

T.C.

[Jeffintampa]

Thanks again

guys I cant thank you enough for all the help.....I ordered a new gasket, new springs (the good ones everyone said to get) and a new clutch cable.

So I guess the plan is to..

Drain the oil, take the exhaust, foot peg, brake lever off, gas tank, and cover, I am going to install the new springs put the MMO in like top cat said, change the oil to the oil you all suggested, and install a new cable.

cross your fingers for me and thanks again.

Jeff

[TopCatGr58]

Hey Jeff,

Hold on a minute. You shouldn't have to take the exhaust, brake lever, footpeg OFF to remove the clutch cover. Once you loosen the nut on the footpeg bolt, the peg will just swivel UP out of the way. Granted, I have aftermarket pipes and not OEM, but they shouldn't be in the way of getting to the bolts that secure the cover...but I could be wrong...this would be a good place for someone with OEM pipes to chime in if they can remove the cover without dropping the the exhaust.

The Gas tank, yes so you can remove and reroute the cable for the least type of bends.

Sorry you ordered the gasket, we usually recommend to just use Threebond , Yamabond, or similar sealant/gasket maker instead.

T.C.

[BA80]

I agree with all you've said TC. However, it's much easier to deal with the reinstalling of the cover with the foot peg completely off and out of the way. It's no big deal to take it off.

Just my experience.

[red bandit]

I have OEM pipes. No need to take them off or even loosen them to remove clutch cover.

[dpotter58]

I have OEM pipes. No need to take them off or even loosen them to remove clutch cover.

Just took mine off last night to change the springs. I couldn't get to one of the allen head bolts to loosen it without swinging the foot peg up.

[trbig]

One trick I've learned with that clutch cover.. They can be very stuck on there and there's no good spot to get to to try to pry on it a bit. I've pulled off the cap where you fill it with oil and used a wooden dowel rod down into that hole to pry with, but what I now do is just leave the clutch cable all hooked up. When you have all the bolts out of the cover, squeeze the clutch lever at the handlebars and this usually pops the cover loose. If not, have someone else squeeze the handle while you tap on it with a rubber hammer. Then disconnect the cable after it is loose. Just thought I'd post this tip AFTER Potter took his off already. lol.

[dpotter58]

If not, have someone else squeeze the handle while you tap on it with a rubber hammer. Then disconnect the cable after it is loose. Just thought I'd post this tip AFTER Potter took his off already. lol.

Thank you Obi Wan.... The farce is strong within you

[Jeffintampa]

well....

I went ahead and dumped my oil, took the foot peb off and brake lever. I did look and dont think the mufflers will have to come off. My chiltons book said take it off. The gasket was only like 5 bucks on ebay no biggie. Cable and gasket came in todays mail, so hopefully get a little start on the project, miss being on 2 wheels. Been having to drive my car UGH.....Drive the bike full time to work every day rain or shine

[trbig]

Just pay attention on re-assembly. It's hard to tell your first couple times doing it if the clutch basket is fully seated. You'll twist, wiggle, shake, pull up and down, left and right, swear something isn't right, then all the sudden it clunks home.

[skids]

Just pay attention on re-assembly. It's hard to tell your first couple times doing it if the clutch basket is fully seated. You'll twist, wiggle, shake, pull up and down, left and right, swear something isn't right, then all the sudden it clunks home.

That is right. The oil pump sprocket (I think) is the gear that can easily get messed-up if things don't mesh. It is thin and is easily bent.

[Jeffintampa]

Status

Well springs came in today, so I pulled the cover, undid the 5 bolts holding the springs in, took the springs out and put the new ones on, now I have started the bolts back in all are snug, I went around and around till they all are snug How tight do I put the bolts in that hold the thing that pushes the springs?

[BA80]

7.5 ft lbs

Before you do that. Did you check to see if the bolts were stretched up near the head. It will be pretty obvious if they are. If they are they could break when you tighten them.

Sorry, should have mentioned it before.

[Jeffintampa]

bolts looked ok

All the bolts looked good 6 of them, I dont have a torque wrench what should I do