Author Topic: Need some thoughts or suggestions on my clutch (Read 973 times)

Chrisr · « **on:** May 14, 2013, 10:23:06 am »

I have another topic up showing the damage on my clutch. Well.........I got the new parts and installed them and the clutch won't disengage. Replaced hub, pressure plate, EBC dirt racer clutch kit, now spring bolts and new bearings on the rack and basket. I went as far as putting a cresent wrench on the clutch arm to pull it and the clutch still won't disengage. The clutch basket was a little buggered up on the outside edge. I filed on it and the discs slide smoothly......but could it possibly be out of shape or mabey a burr I missed holding the pressure plate? I ran it around the yard for a few minutes in case the clutch was just stuck but no help. Any suggestions?

Dezsled · « **Reply #1 on:** May 14, 2013, 11:02:05 am »

You probably checked but did you align the rack with the gears on the clutch arm when you installed the side cover?

Chrisr · « **Reply #2 on:** May 14, 2013, 11:39:39 am »

Quote from: Dezsled on May 14, 2013, 11:02:05 am

You probably checked but did you align the rack with the gears on the clutch arm when you installed the side cover?

Yeah I checked that. When you twist the clutch arm you can hear the rack move and feel when it touches the pressure plate.

BadMoonRacing500 · « **Reply #3 on:** May 14, 2013, 12:48:17 pm »

Cable adjusted correctly?

Stpltn250r · « **Reply #4 on:** May 14, 2013, 01:37:49 pm »

When you take the clutch cover off does the pinion shaft and clutch arm move?

Look closely to where the clutch rack goes into the cover to mate with the pinion shaft. That area could be ****. Only other thing I can think of is springs binding up.

Maybe you were sent the wrong clutch entirely and its stack height its to much and the pressure plate isnt resting inside the grooves of the inner hub. Or you put the plates in to where there is a steel towards to end of the pack and the pressure plate is binding up against it.

Chrisr · « **Reply #5 on:** May 14, 2013, 02:21:05 pm »

Quote from: Stpltn250r on May 14, 2013, 01:37:49 pm

When you take the clutch cover off does the pinion shaft and clutch arm move?

Look closely to where the clutch rack goes into the cover to mate with the pinion shaft. That area could be ****. Only other thing I can think of is springs binding up.

Maybe you were sent the wrong clutch entirely and its stack height its to much and the pressure plate isnt resting inside the grooves of the inner hub. Or you put the plates in to where there is a steel towards to end of the
pack and the pressure plate is binding up against it.

The clutch arm does move when the cover is installed or removed. Thats a good point on the possibility of the cover being **** where the rack goes in. there was a clutch spring and bolt bouncing around in the at one time. Im going to pull the clutch cover when I get home from work and and check it all out. I ordered another basket today. Figured everything else is new so whats another $150.00.

BadMoonRacing500 · « **Reply #6 on:** May 14, 2013, 03:14:44 pm »

I've had the shaft for the clutch arm get really sticky in the case also. It may need to be taken out of the clutch cover and cleaned.

Chrisr · « **Reply #7 on:** May 14, 2013, 08:01:05 pm »

Thanks for the ideas. I'm pulling the clutch cover when I get home later and checking everything again. I've got a sneaky feeling it may be where the rack goes into the cover. I got a few nice chunks of metal from around the pinion shaft gear where it engages the rack. I wonder if the cover possibly got out wollowed out around the bottom of the pinion shaft.

Dezsled · « **Reply #8 on:** May 14, 2013, 08:14:40 pm »

Coil bind the springs upon assembly? Just throwing out ideas

BadMoonRacing500 · « **Reply #9 on:** May 14, 2013, 08:23:48 pm »

Clutch springs are 5ft/lbs of torque

BadMoonRacing500 · « **Reply #10 on:** May 14, 2013, 11:21:31 pm »

Did you index the clutch pinion with the clutch arm shaft in the clutch cover? When putting the clutch cover on? Pull the pinion all the way out. Then as your putting the cover on you must turn the clutch arm shaft to suck the pinion up against the pressure plate. from their re-adjust the arm and cable.

Chrisr · « **Reply #11 on:** May 17, 2013, 07:44:11 am »

I checked and rechecked everything, put in a new clutch basket and it still won't disengage. Only other thing I can think of is put coolant in it and let it run while I work the clutch lever in case it's stuck. Short of rolling it into the pond I don't know.

Dezsled · « **Reply #12 on:** May 17, 2013, 08:29:43 am »

What's the length of your clutch springs? Gotta check the free length

Your saying the clutch won't disengage normally? Lever won't pull in?

Chrisr · « **Reply #13 on:** May 17, 2013, 08:58:25 am »

Quote from: Dezsled on May 17, 2013, 08:29:43 am

What's the length of your clutch springs? Gotta check the free length

Your saying the clutch won't disengage normally? Lever won't pull in?

You can pull the lever as normal and the clutch won't disengage. Clutch cable is new, all slack is adjusted out and the clutch arm is in the 11 o'clock position with slack taken out of the pinion. Spring length would be the one thing I didn't check. I'm using the springs that came with the EBC kit, doesn't say much I know.

Rider414 · « **Reply #14 on:** May 17, 2013, 06:46:04 pm »

Can you feel the clutch pack spring resistance when you pull in the clutch? Like normal?

Dezsled · « **Reply #15 on:** May 17, 2013, 07:05:21 pm »

I'm sure you did, but did u install the thrust washer (needle bearing washer) on the rack when installing the pressure plate/clutch springs/bolts & washers?

Chrisr · « **Reply #16 on:** May 17, 2013, 10:10:35 pm »

Quote from: Dezsled on May 17, 2013, 07:05:21 pm

I'm sure you did, but did u install the thrust washer (needle bearing washer) on the rack when installing the pressure plate/clutch springs/bolts & washers?

Thrust washer is on but you mentioning the spring length has me wandering about that. I used the EBC springs that came with the kit. Mabey the spring is too thick or too long and collapsing before the pressure plate releases the clutch pack fully? The clutch cover has to come back off anyways so I'll do some measuring.

Chrisr · « **Reply #17 on:** May 19, 2013, 09:32:04 pm »

I compaired the compressed length of the EBC vs factory springs and the EBC spring was 1/8" longer than factory when compressed.

LT250RWV · « **Reply #18 on:** May 19, 2013, 11:18:46 pm »

I used ebc spring in mine and didnt have a problem from them. Take some pic of your clutch so we can where your problem is.

Chrisr · « **Reply #19 on:** May 20, 2013, 09:13:18 am »

Had 6 brand new factory springs come in the mail today.........put them in and I now have a properly working clutch. Must have been a Friday afternoon kit from EBC and someone put the wrong springs in it.

Dezsled · « **Reply #20 on:** May 20, 2013, 09:48:13 am »

Good to hear its fixed

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Author Topic: Need some thoughts or suggestions on my clutch (Read 973 times)

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