Clutch issues

[dbeardslee]

So I just put a new clutch in my brother's 80G, and it appears that doggone lever on the cover plate came loose. I didn't move the lever when it was off the bike, but it didn't have a return spring on it, so maybe it moved just from moving the cover around. So my question is this - how tricky is it to disassemble and reassemble the pusher assembly?

[3Phase]

Doug,

The balls for the clutch throwout bearing lever assembly are supposed to be held captive in a cage/ring so they can't drop down into the engine if the adjusting screw is too loose. You may have to pull the clutch cover but you could get lucky!

If you're lucky you just take off the clutch cable, back out the adjusting screw and work the lever around until the balls to move back into place in the assembly. If they move back into place, hold the lever and tighten the adjusting screw to hold the balls, then re-attach the clutch cable and set the lever travel.

If you're not lucky you have to do the same thing but with the clutch cover removed. Put the bike on the sidestand so you don't have to drain the oil.

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[dbeardslee]

Thanks for the reply, 3P. I already went over to Yamaha's parts site and looked at a diagram, and it looked pretty simple. I wanted it done by the time my brother got home, so I took the cover off and completely disassembled it. I also went up to sears and got a suitable return spring, and installed a new o-ring while I was at it.

But you're right - I probably could have just fiddled with it and got the balls back in the sockets. At least now I KNOW what's in there, and if it happens again I'll be ready.

[BowlingSS]

Did you replace the clutch springs also? I was told the springs should also be replaced.

Bill

[dbeardslee]

Did you replace the clutch springs also? I was told the springs should also be replaced.

Bill

I replaced them with heavy duty clutch springs. It makes the lever a little heavier, but you get really positive engagement.

I also learned something about adjusting the clutch by disassembling the pusher mechanism. Initially I adjusted the clutch as per "normal" - in till lightly seated and backed off 1/8 turn. That gave me a clutch that started engaging as soon as the lever started to move out - and that was after diddling with the cable length adjustment at the handlebar.

As I adjusted it in a bit farther at the cover plate I found that it moved the clutch engagement out farther on the lever. The result was a lever that wasn't quite so heavy, with about 1/2" movement before it started to engage. No slippage under heavy throttle, and no creep while stopped.

[BowlingSS]

I will be replacing my plates and springs soon. They are just waiting for me.

Bill

[trbig]

I will be replacing my plates and springs soon. They are just waiting for me.

Bill

Plates almost never go bad or get out of spec. Stock springs, and most replacement springs, go bad a lot. I was going through a couple sets of springs a year until I found the Barnett springs. I can't tell you exactly how many years are on the now, but never a slip with them. It does increase the handle pull quite a bit though for those fighting arthritis, carpel tunnel, or just plain limp-wristedness.

[dbeardslee]

I dunno if you guys heard about the naked guy north of cincinnati who wrecked his truck (along with six other cars) on I-71 and then went for a jog down the highway, but I just happened to be out for a test drive on Betsy at the time. He REALLY backed up traffic, and it was creeping along at a speed that wouldn't allow me to stop, nor let the clutch out all the way. Betsy's got hd clutch springs, and it took about 1/2 hour to make it to the next exit. MY GAWD was my hand sore!!!

[BA80]

I dunno if you guys heard about the naked guy north of cincinnati who wrecked his truck (along with six other cars) on I-71 and then went for a jog down the highway, but I just happened to be out for a test drive on Betsy at the time. He REALLY backed up traffic, and it was creeping along at a speed that wouldn't allow me to stop, nor let the clutch out all the way. Betsy's got hd clutch springs, and it took about 1/2 hour to make it to the next exit. MY GAWD was my hand sore!!!

When stuff like that happens I'll go to the shoulder and pass until I get to an exit. These engines get too hot without air flow.

[dbeardslee]

When stuff like that happens I'll go to the shoulder and pass until I get to an exit. These engines get too hot without air flow.

Believe me - I was thinking about exactly that. But around here that's illegal. Not to mention if everyone did that, well... you do the math. If she had started to act like she does when overheating I would have pulled over on the shoulder and shut her down 'till she cooled off. Luckily it wasn't that hot out, and she got through it fine.

[BA80]

It's pretty much illegal everywhere but a ticket is less expensive than an engine.

[dbeardslee]

I figure the shoulder is for emergency stopping - not passing. If I had to stop, that's what I'd do. But nobody likes it when someone uses the shoulder for their own personal lane.

[3Phase]

Yeah, here in California you can lane share but you may not pass on the right or ride on either shoulder. They'll write you up in less than a heartbeat, too many SQUID.

.

[BA80]

IBut nobody likes it when someone uses the shoulder for their own personal lane.

Nobody likes me anyway.

I'm pretty sure that a car doing that would be objectionable but on an air cooled engine motorcycle in standstill traffic it would be understandable to most, even LEOs. It's not like it's 8 feet wide and causing issues. No more objectionable than splitting lanes and actually less dangerous.

[dbeardslee]

Yeah, here in California you can lane share but you may not pass on the right or ride on either shoulder. They'll write you up in less than a heartbeat, too many SQUID.

.

SQUID? I had to look that one up. Lol