MrMogensen
... That's me!
New clutch - Not enough spring-action... SOLVED!
Installed a new clutch (a set with compression springs, friction plates and clutch plates).
The whole operation was quite easy except refitting the clutch cover onto the pull rod. I followed the steps of the "2004 Service Manual" (around page 5-54), aligning the punchmarks on the pull lever and clutch cover.
I checked the pull rod lever action and it seemed to work with about the same resistance as with the old clutch. Looking down through the oil refilling hole I can see the pull rod move in and out so I thought I was home free.
The situation...
Refitted the clutch cable just to the pull lever just to find out that the return-spring-action is too sloppy. The pull lever can barely make the clutch lever return to normal position.
Clutch cable was fitted last year so that shouldn't be the cause of the problem. The clutch lever action feels soft. The old clutch cable action was getting hard and rough so I think I know what it should feel like.
Question: When looking down the oil refilling hole... Should I be able to see the whole clutch arrangement + pull rod moving when I push the pull lever (and the pull rod is moving)? Can't really see the whole arrangement moving so I really suspect that I have not hit the right spot between pull lever and pull rod?
Have tried to refit the pull lever on the pull lever shaft but doesn't change a thing - I mean refitting to another angle so I got more room to pull, but the total degree of movement does not change. I thought that I might have been in some slack area but possibly not.
NOTE: I have not yet started the bike, because I am waiting for the airfilter to dry after cleaning (K&N filter).
I know I most likely need to take that darn clutch cover off again :thumbdown:... but maybe one or more of you got some good ideas/solutions before I do?
Question: "Of course" I just topped op with fresh oil... If I put the bike on the sidestand will the oil-level stay below the bottom of the clutch cover?
Installed a new clutch (a set with compression springs, friction plates and clutch plates).
The whole operation was quite easy except refitting the clutch cover onto the pull rod. I followed the steps of the "2004 Service Manual" (around page 5-54), aligning the punchmarks on the pull lever and clutch cover.
I checked the pull rod lever action and it seemed to work with about the same resistance as with the old clutch. Looking down through the oil refilling hole I can see the pull rod move in and out so I thought I was home free.
The situation...
Refitted the clutch cable just to the pull lever just to find out that the return-spring-action is too sloppy. The pull lever can barely make the clutch lever return to normal position.
Clutch cable was fitted last year so that shouldn't be the cause of the problem. The clutch lever action feels soft. The old clutch cable action was getting hard and rough so I think I know what it should feel like.
Question: When looking down the oil refilling hole... Should I be able to see the whole clutch arrangement + pull rod moving when I push the pull lever (and the pull rod is moving)? Can't really see the whole arrangement moving so I really suspect that I have not hit the right spot between pull lever and pull rod?
Have tried to refit the pull lever on the pull lever shaft but doesn't change a thing - I mean refitting to another angle so I got more room to pull, but the total degree of movement does not change. I thought that I might have been in some slack area but possibly not.
NOTE: I have not yet started the bike, because I am waiting for the airfilter to dry after cleaning (K&N filter).
I know I most likely need to take that darn clutch cover off again :thumbdown:... but maybe one or more of you got some good ideas/solutions before I do?
Question: "Of course" I just topped op with fresh oil... If I put the bike on the sidestand will the oil-level stay below the bottom of the clutch cover?
Last edited: