Posts
92
Joined
5/18/2017
Location
Homestead, PA
US
Edited Date/Time
8/6/2017 3:57pm
Rebuilding my engine and got things all back together yesterday but when I attached the clutch cable to the pin, it doesn't move at all. It seems like something is locked up inside the motor. I took the clutch case and everything inside back apart again today, reassembled according to the diagram in the manual, and it still will not pull. Everything inside spins as it should it's just when I put the case cover on things get tight. It is the correct case and I'm thinking possible the rack pin isn't right or something. I can only get the case together when the rack teeth are facing the teeth on the clutch pin.
I don't know what else to do now. Someone suggested a bearing in the case that the rack sits on might be missing but I don't see a bearing in that area in any schematic nor do I recall removing one on the disassembly. I've ruined two gaskets thus far and have a helluva time getting the cases together without the freaking kickstart spring popping out.
I'm at a loss here. Any suggestions would be welcomed!
I don't know what else to do now. Someone suggested a bearing in the case that the rack sits on might be missing but I don't see a bearing in that area in any schematic nor do I recall removing one on the disassembly. I've ruined two gaskets thus far and have a helluva time getting the cases together without the freaking kickstart spring popping out.
I'm at a loss here. Any suggestions would be welcomed!
I'm preparing a second cover I have from my parts just in case. I'm wondering if maybe the clutch basket I have in there is out of round? I may try putting the old one back in and seeing what happens.
Thanks, hare!
Paw Paw
The Shop
Below is a pic of the basket setup I have now installed with the plates.
Yes, I can't get the clutch lever to move when I install it. I even tried getting the plates to disengage with the cover off today and they ain't budging! I don't know if maybe this is normal and will work when the engine is fired and warm. It just seems wrong to me as I thought you could pull the clutch lever and open the plates any time.
I'm thinking of springing for the Mitaka basket but would hate to have it not work also.
I'm at a loss here. I have taken it all apart a half dozen times now and reinstalled it according to the diagram and still nothing. I don't know....
When the clutch cover was on, the clutch arm with the cable in it was pointing up to 12 o'clock.
On the kickstarter spring, is it supposed to sit cockeyed of the left side? That seems to me like it may be what's causing the clutch cover to be so friggin hard to get on. Should that cover simply slide on easily or do you have to fight it a little bit?
Lastly, I tried shifting gears with the shifter today before taking the clutch basket and plates off again. It seemed to shift into gear and back to neutral again. When I removed the clutch basket and plates and tried shifting gears, it seemed like it was in neutral no matter what I did. Is that normal without the clutch installed?
I appreciate the offer also. Hopefully I can get this figured out on my own. I'll keep you posted. Do you have a regular email address?
The clutch cover should go on relatively easily.
The kicker spring being off center isn't going to be a problem unless its so bad it ends up between the case and the plastic sleeve on the kicker shaft. What will cause a problem is if the kicker spring end pops out of the hole it's supposed to be in. I'm assuming that's not what happened because if it is, you cannot get the cover back on.
As for the transmission acting like it's in neutral when the clutch basket off, it's entirely normal. There's nothing tying the transmission input shaft to the crank at that point.
I ran a Mitaka basket in my 1991 RM250 for several years...it's a good piece, no problems whatsoever. Just follow the instructions on how to attach the gear to it and you'll be fine.
Lastly. when you install the clutch basket, the gear on the back of it should line up with the kicker gear and the primary gear on the crank. There should not be an offset between them, so they get full width engagement. I didn't see this before, and it's difficult to see from the pic you provided, but it looks like your primary gear (and the entire clutch assembly is too far out.
I have a quick video I shot to show the situation. I can get the clutch pin to turn to the left but not to the right. Turning to the left will actually move the case out away from the engine so it's obvious the pressure plate is moving. I just can't understand how to reverse this!
Maybe, I don't know, this is all correct and there isn't a problem. I know when I attach the cable and pull the lever, it doesn't budge so I'm assuming the clutch is not opening.
email to" krv123 @comcast.net
Also, you are going to be hard pressed to be able to rotate that arm by hand. You just don't have the leverage to do so.
Paw Paw
There are no marks that I can see on the arm so I'm basically winging it and hoping for the best. I can only get the cover on, though, when things are lined up perfectly. The damn cover is a real SOB to get on with a lot of wiggling around. It definetely isn't a smooth install.
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