OK so im new at this. I just pulled the compensator and primary to change the starter pinion gear. had some trouble getting the clutch adjusted using the manual. the problem seemed to be the ramp on the opposite side of the trans was stuck. I took it out for a shakedown run and it ran great until a 1-2 shift after about 20 minutes of riding. clutch seems to slip? in any gear 1-4 (5th gear still seems to work), the bike will not move forward. I pulled the primary cover and verified the clutch rotates when the engine is running. When I squeeze the handle the clutch hub moves. Where should I go from here?

 

I just tried to re adjust the clutch and the same thing. If its on the stand, running, I can put it in gear and release the clutch. Nothing happens until i run through the gears and reach 5th which grinds.

 

Did you perform the diaphragm spring adjustment before you adjusted the clutch and cable?

 

I'm not sure how accurate it was since i didn't have a .010 feeler gauge

 

OK so I replaced the clutch thinking that it was the fluid I had used and the clutch discs were destroyed from being soaked in the wrong fluid. Buttoned it all up and fired it up....Nothing.

So i took the whole primary drive apart. I have discovered that fifth gear still functions but 1-4 do not. spinning the rear tire by hand in 1-4 doesn't allow the input shaft to spin under any load. however 5th gear is firm and spins the shaft.

 

Bump for help

 

Maybe you know what that means, but it doesn`t give us much to go on.

Tell us exactly what happened.

What did you remove?


Are you saying that when the transmission is in 1st-4th gear, you can turn the rear wheel and the mainshaft does not turn?

Are the clutch,primary chain and compensator still installed?

 

Maybe you know what that means, but it doesn`t give us much to go on. Removed and replaced all components inside the primary housing. adjusted the clutch per the manual, and filled with fluid.

Tell us exactly what happened. Pull in the clutch handle put the transmission in gear and release the clutch no forward movement in first through fourth gear.


What did you remove? Compensator sprocket, chain, adjuster and the entire clutch hub.




Are you saying that when the transmission is in 1st-4th gear, you can turn the rear wheel and the mainshaft does not turn? The main shaft that the primary clutch housing is on

Are the clutch,primary chain and compensator still installed? No sir they are not. I took it all off today to see if I spun the key on the primary clutch shaft.

 

The keyed shaft that the clutch mounts onto is the mainshaft. The big splined shaft that the front belt pulley mounts onto is called the main drive gear. The countershaft is forward of the mainshaft inside the transmission case and not visible.

Since you already have the clutch/compensator/primary chain removed, I suggest you remove the inner primary cover and check the torque on the front belt sprocket (pulley), the pulley nut is left hand thread. The pre `94 bikes were notorious for loosening pulley nuts, which could allow the pulley to come loose and wipe out the splines on the pulley and the shaft.

While you are in there, check for leaks on any of the transmission seals, and check the integrity of the shift lever, make sure it is tight on the shaft (no wobble whatsoever).

 

Thanks Dan, the only part hard for me to grasp is the fact that fifth gear still works. (rotates the tire and visa versa) I know that fifth gear is on the main transmission input shaft. So, my problem must lie inside the trans.