1994 clutch adjust problems

Reply Subscribe

Thread Tools

Search this Thread

Mar 29, 2015 | 04:33 PM

Codyyy

Thread Starter

Intermediate

Joined: Jan 2013

Posts: 36

Likes: 0

From: San Diego

1994 clutch adjust problems

I've put on the clutch unit, chain and compensating sprocket. Torqued them both to spec. I did not take apart the clutch unit, just took it off. Now the clutch adjusting washer/shaft and jam nut combo are too "long" and will not seat all the way into the clutch to allow me to put the snap ring in. I decided to loosen the jam nut and back out the shaft in order to put the snap ring in. The clutch cable was adjusted all the way out to slack already. I cannot seem to adjust the cable close to spec and the threaded adjusting shaft is a lot farther out than it was before.The manual said to put the transmission in 5th gear in order to loosen the main shaft nut, I'm assuming the transmission now needs to be in neutral in order for the jam nut and clutch cable to be adjusted? This is probably a simple fix but I'm confused at this point. Thanks.

Mar 29, 2015 | 05:14 PM

glidein wide

Stellar HDF Member

Joined: Jan 2015

Posts: 2,504

Likes: 150

From: ct

Is it possible that the clutch cable end came out of its pocket at the tranny end?

Mar 29, 2015 | 05:19 PM

glidein wide

Stellar HDF Member

Joined: Jan 2015

Posts: 2,504

Likes: 150

From: ct

Also,it seems like the clutch assembly is not seated properly on the shaft or washer/ spacer, something changed on ya.

Mar 29, 2015 | 05:43 PM

RidemyEVO

Stellar HDF Member

Joined: Apr 2009

Posts: 3,039

Likes: 11

From: Northern Ontario

Loosen off the cable and adjuster nut on clutch and start over with the adjuster nut making sure it seats then back off as per manual and adjust cable as per manual, if this doesnt work sounds like you have to pull the cover that holds the clutch cable , could be sprung. Sorry not sure on the lingual for the cover on gearbox.

Mar 29, 2015 | 10:09 PM

Codyyy

Thread Starter

Intermediate

Joined: Jan 2013

Posts: 36

Likes: 0

From: San Diego

I'll check it out on the transmission side or just unscrew it from the transmission and do it over again. It seems like the clutch cable is too long no matter how much it is adjusted inward. The clutch itself went onto the splines just fine, I have not seen a spacer of any kind go between the clutch and the inner primary housing. I checked the parts manual to be sure. Unless I somehow lost a spacer and cannot find it in the diagrams. It seems weird to be that the manual says to adjust clutch, then adjust primary chain, then put together the outer primary and finish it up. Then in the clutch adjustment section it says to put the bike level and adjust it that way. I'm thinking I'll just adjust it twice.

Mar 30, 2015 | 08:56 AM

ajayrk

Road Master

Joined: Jul 2007

Posts: 1,009

Likes: 4

Clutch ramp has gone over center. Remove filler plug and use a screw driver to push it back into place. You may not have an EZ pull installed but you can see where the ramp should be.

Attached Thumbnails

Last edited by ajayrk; Mar 30, 2015 at 09:38 AM. Reason: image

Apr 4, 2015 | 06:51 PM

Codyyy

Thread Starter

Intermediate

Joined: Jan 2013

Posts: 36

Likes: 0

From: San Diego

It ended up being the clutch cable ramp. I drained the transmission case and took off the side cover just to make real sure the cable was on and hadn't popped off accidentally. I put the cover back on and adjusted the clutch according to the manual... worked easy. Thanks again.