Clutch Problems

crash32
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crash32
Edited Date/Time 1/27/2012 3:58pm
We are having some clutch issues or something on a 1996 YZ125.
Just some history first. I have replaced all the clutch parts (clutch boss, basket, fibers and plates) All are factory parts.
Now when we start the bike it seems to go into gear but when you let the clutch out it does not go anywhere.'Seems like the clutch is engaged all the time! The lever springs back fine and everything.

Any ideas would be great.

Thanks
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scooter5002
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scooter5002 10/30/2011 7:20pm
10/30/2011 7:20pm
How much free play at the lever?
MOTODAD422
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MOTODAD422 10/30/2011 8:46pm
10/30/2011 8:46pm
Pressure plate not clocked correctly. I believe it only goes all the way in one way.
crash32
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crash32 10/31/2011 6:41am
10/31/2011 6:41am
Thanks for the replies.

There is a quarter play at the lever.
Motoda422 could you explain this for me.
Sorry I don't understand what you are trying to say.

Thanks
scooter5002
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scooter5002 10/31/2011 8:44am
10/31/2011 8:44am
My guess would be that he is saying that the pressure plate (the one that takes the bolts through it) only fully seats one way. A "master spline position" if you will. Think keyway on the crank for your flywheel. Don't know if that is the case or not with that bike. I've never seen it, but that means nothing. Other than I've never seen it. Do you have a manual you can check? It will tell you.

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scooter5002
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scooter5002 10/31/2011 8:47am
10/31/2011 8:47am
I guess the next question would be were they ALL the right parts you put in? If you didn't double check part numbers before you installed, that could be part of it. Been bitten on that before. Sent me all the parts I ordered. Just not the right ones. Lol.
crash32
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crash32 10/31/2011 9:42am
10/31/2011 9:42am
Thanks for the reply

I have the manual and it seems everything is OK.
We will have to take it apart and check the part numbers but everything was suppose to be stock except the fibers and plates.

Thanks
lumpy790
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lumpy790 10/31/2011 10:54am
10/31/2011 10:54am
remove all clutch springs. Rotate outer pressure plate one spring hole at a time noting how far in it goes...... one will go all the way to the clutch plates.
crash32
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crash32 10/31/2011 1:26pm
10/31/2011 1:26pm
Thanks lumpy790 we will take it apart again and look to see if rotating the outer pressure plate is it.
MOTODAD422
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MOTODAD422 11/1/2011 1:27pm
11/1/2011 1:27pm
lumpy790 wrote:
remove all clutch springs. Rotate outer pressure plate one spring hole at a time noting how far in it goes...... one will go all the way...
remove all clutch springs. Rotate outer pressure plate one spring hole at a time noting how far in it goes...... one will go all the way to the clutch plates.
Thanks lump I was thinking of a way to explain it.
crash32
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crash32 11/1/2011 5:56pm
11/1/2011 5:56pm Edited Date/Time 11/1/2011 6:25pm
Thanks for all the help guys.
We did some checking today and found out that no matter what way you put in the outer clutch plate it sites the same.
So we put the old clutch plates and fibers in the new clutch parts and found it sits tighter to the outer clutch plate.
I think they might have ordered the wrong plates and fibers for the bike! They ordered EBC DRC Kevlar Series Complete Clutch Kit.
When we put the new ones back in it almost seems like it needs another one to make it sit tight.

Is there that much difference in plates and fibers?

Thanks

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