Putting bike together after too long, been busy riding other bike. Replaced secondary drive belt and putting clutch back in I followed service manual about backing out adjust screws 1/2 turn. Working at clutch cable I could not get any adjustment on lever. Way to much cable. Looking at diagram I put in main shaft nut, release plate, adjusting screw and internal retaing ring. There seems to be missing diaphragm spring, clutch spring plate and another internal retaining ring. I don't remember taking these out nor do I have these parts in a labeled bag. (I label and bag everything) if these are missing does that explain why I can not adjust clutch. The push rod I was able to push back into clutch to where it is not up against adjusting screw. Something is terribly wrong. I do have 2 internal retaining rings, one with shoulders on ends and the other no shoulders but no diaphragm spring or clutch spring plate ???

 

What year is your bike?

Sounds like your ball and ramp assembly isn't seated and your clutch adjuster wasn't seated when you started your adjustment. Meaning your clutch adjustment is off.

 

Ball and ramp?

 

It’s under the trans cover where the clutch cable goes into it. It is what pushes the rod causing the clutch plates to separate.

 

Tx for that! Yes, I checked that out. That is fascinating how that works. Apparently when I over loosened the adjuster nut on cable it fell apart. I've been in a hydraulic system on newer bikes so was familiar with how they work. The clutch cable on this bike is "old school'. Got this bike from my pop who lost ability to ride bc of age.

 

There should be a large snap ring holding the ball and ramp pieces in place. I don’t think loosening the adjustment cable can defeat the snap ring. Maybe the snap ring wasn’t seated properly.

 

Yes, you're right. Good point. Opened it up to check it out and it seemed to all be in place. So something else is the matter, I'm still wondering if I'm missing something on the other side. Will look more into that.