beiswtj Posted May 13, 2007 Share Posted May 13, 2007 The pull rod has play in it, like it is floating in no-man's-land. So I install the cover, slide the pin down the slot, and it hooks up to the pull rod in the clutch. When you rotate the pin to hook up the clutch cable, it will only rotate a little bit, just like the pull rod is only moving about in the no-man's-land area. It's not springy. Now with that said, here's the background...I was riding home the other day and the bike wasn't shifting right. I get home and found that it had developed an oil leak, and was low on oil. The low oil idiot light had not come on though. So I fixed the oil leak(crank seal), and started up the street. However, it was now nearly impossilbe to shift. I could get it from first to second, and when I pulled the clutch lever you could hear some squealing, but the clutch did seem to disengage the trans. So I got back to the house, pulled the cover off and just looked at the clutch. Didn't see anything, not that I knew what I was looking for. However, now the shift lever is freed up, and can be operated by hand. Put the bike in neutral and I can move it back and forth without hearing any moaning or squealing(before I took the cover off the bike was hard to move even in neutral like something was binding). I had originally assumed that I fried the trans, but now I'm thinking the clutch is the problem. It's just weird to me that the clutch lever worked fine until I took the cover off, so I'm obviously doing something wrong. Sorry for being so long, but I'm thoroughly confused. Link to comment Share on other sites More sharing options...
Moderator YamaHead Posted May 13, 2007 Moderator Share Posted May 13, 2007 The vertical rotating rod that's inside the clutch cover, has a flat side on the end near the clutch hub.... Sounds like you might have that flat side pointing away from the hub....thus not actuating the clutch assembly correctly. Drain the oil....pull the clutch cover off & rotate that rod so the flat side on that end is pointing towards the clutch hub. Reassemble & then adjust the cable for proper feel. Hope this helps Link to comment Share on other sites More sharing options...
beiswtj Posted May 14, 2007 Author Share Posted May 14, 2007 The vertical rotating rod that's inside the clutch cover, has a flat side on the end near the clutch hub.... Sounds like you might have that flat side pointing away from the hub....thus not actuating the clutch assembly correctly. Drain the oil....pull the clutch cover off & rotate that rod so the flat side on that end is pointing towards the clutch hub. Reassemble & then adjust the cable for proper feel. Hope this helps Thanks for the reply, but I'm confident that I've got that part right. Does anybody know if that pull rod is supposed to "float" around like it does? I haven't taken the pressure plate off yet, but my guess is that I'll find a dead throw-out bearing if I do. Link to comment Share on other sites More sharing options...
fj-1200 Posted May 15, 2007 Share Posted May 15, 2007 I had a problem simular to that and found that I was missing a little ball that went in before the push rod,(powersedge.net) is were I find my problem.hope it helps you also. Josh Link to comment Share on other sites More sharing options...
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