I don't know anything about 4 speeds but is there anything that could have come loose on the right side of the transmission when you pulled out the rod?

 

You just made me think about something !!!! Did you make sure the clutch cable is seated back into the arm on the tranny ???!!! Shine a light under the battery and make sure the ball on cable is back in there...

 

How you making out there buddy ??? When you get enough posts under your belt I would like to see pics of your bike...

 

Hope everyone had a good Labor Day. I've been out of town since Friday so i haven't worked on the bike all weekend. Today I'll give it another crack and let you know.

The primary cover is still off so I'll take a measurement of how deep that rod is and its travel. I'm also going to double check the cable. Could something have not seated correctly on the right side?

 

The thing you are calling the pushrod, is it rounded (convex) at both ends and about 10" or 12" long, more or less? If so, that is indeed the pushrod.

The adjuster screw that screws into the plate on the clutch assembly...is that one inch long, more or less, and flat on one side?

If so, then you are missing part #7 from this diagram.

The key here is that the pieces that come into contact with the ends of the pushrod need to also be rounded (concave). If you have a flat adjustment screw and a rounded (convex) pushrod, there needs to be something between them.

 

 

The pushrod is now 1 1/2" inside the mainshaft, too far for the adjustment screw to reach it. And as I said before I pulled the pushrod out with my fingers, no tools needed. That could have been my downfall because I think texashillcountry could be onto something. I think I'm going to have to pull the kicker cover. Also 0maha, that diagram looks to be for a different clutch as my bike doesn't have pushrod ends but I can't find any diagram that supports my theory, not even this clymers manual

 

This not it?


86 WG Clutch

Griz

 

That looks like a '91+ adjustment bolt.

Anyone's guess what you're working with here. Someone has been in there before and replaced stuff.

I think your next step is to pop the right hand side off the trans and see what's what.

 

nope. My clutch doesn't exactly match that diagram. Which makes me believe my situation is as 0maha says and it's been cobbled together. Off comes the kicker cover. Let's hope the problem is self evident in there because soon it's going to be rain for the next 5 months here in Portland.