R66R Posted May 17, 2014 Share Posted May 17, 2014 I'm nearly finished rebuilding my XS850 set in a 750 frame. I didn't touch the clutch outside of removing the cable, as it worked perfectly with full travel and play when I bought the bike and I had made no change to the mechanical pin adjustment. Problem is, cable routed and re-attached, I can't get the clutch to disengage. I did pull the motor, left it wet and upright during the frame off resto (3 months), and did have it lying on it's left side on a garage rug for roughly an hour as I slipped the frame back over and mounted it back up. The cable has full travel. I have played with both the motor and lever linkage adjustments as well as the mechanical adjustment (backing out nut, running screw to 'soft seat' and backing off 1/4 turn) for hours. I have also run the screw in gradually to hard seat while attempting to disengage, hope that wasn't a mistake. It is back at 'soft seat' now, no luck. I can see the pin travel in and back out of the case, but it will not release my shaft and let me spin the wheel. Any help and/or ridicule is absolutely welcome and appreciated! P.S.- As I had the bike on stand mid-disassembly, the tiny wire used by the PO in place of a cotter pin to hold the motor side linkage pin in place snapped under tension and released the linkage. It remained in that position for roughly 4 months before I re-attached the cable and secured the pin properly. Link to comment Share on other sites More sharing options...
Moderator Airhead Posted May 17, 2014 Moderator Share Posted May 17, 2014 perhaps the plates have stuck together, a common enough problem caused by lack of use?, maybe try rocking the bike back and forth in gear with the clutch pulled and a hot engine? Link to comment Share on other sites More sharing options...
R66R Posted May 17, 2014 Author Share Posted May 17, 2014 Been afraid I can't start it without being able to pull the clutch, can I? In neutral without pulling in the clutch lever, I can kick it and hear and feel the travel through the motor (kick only with points, starter is still on the bike with no solenoid or button in circuit). But, with the clutch lever in and in neutral, there's only light resistance on the kick lever, no travel on the gears. In 1st with the clutch lever in, it drives the wheel as though they're engaged. Thank you Airhead. I'm new to all bikes, thought I had to be in neutral, clutch in, choke out, power on. Can I start in neutral, no clutch? Link to comment Share on other sites More sharing options...
blackhat250 Posted May 17, 2014 Share Posted May 17, 2014 But, with the clutch lever in and in neutral, there's only light resistance on the kick lever, Aha" this is like my H2 ,, the kickstart is on firstgear via the cluch-primary gear to start engine , pull in clutch -and kicker just slides. You need her in neutral. same if you stall the bike at light, .. be ok when electric start works, Link to comment Share on other sites More sharing options...
R66R Posted May 17, 2014 Author Share Posted May 17, 2014 Started up fine, thank you man. Plenty of tuning to do. Going to go through the exhaust clearcoat cure cycles and sync the carbs, adjust timing. No progress yet on the clutch while hot, but i'll get right back to you when it's had a proper back and forth. Link to comment Share on other sites More sharing options...
R66R Posted May 18, 2014 Author Share Posted May 18, 2014 Got it hot and it slipped right in... I bit of cable adjustment and cycles through all 5 gears just fine.Thank you for the help mate! 1 Link to comment Share on other sites More sharing options...
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