Here is the deal...I looped my bike (954) a few weeks ago, 2nd gear. After I picked the bike up it had poped into Netrual and I noticed that there was absolutly NO tension on the clutch.

After taking the clutch cover off, one the the spring bolts had busted and the nipple on the center clutch where that spring and screw bolt into busted. I have recently gotten a new center clutch and 5 new springs and bolts. Nothing else inside the clutch or up inside the motor looked damaged in anyway.

After putting everything back together I still had just about NO clutch tension. I adjusted the main adjuster by the cover All the way out and the clutch lever adjuster is almost all the way out just to get the freeplay back to normal, and even then the little amount of freeplay just doesn't feel right to me.

What the Heck is wrong? I've tried everything and can not figure this one out.

 

check your cable. if you flipped it hard enuf to break internal **** it could break or stretch the cable

 

That was acually my last thought. The cable is not broke or busted but I really just didn't think that it would have streched that much. Its worth a try though....

Any other advice is appreciated.

Thanks, :YEAH

 

Your clutch lifter pin is broken. Mine did the same thing once when I crashed......Hold on I gotta pic of my broken one somewhere I will see if I can find it.

 

Here is the pic...The thing I circuled is the "clutch lifter pin" It should have a head on it. It shouldn't be just a straight shaft. The head is really easy to break off of it when you damage the clutch cover, because it sits inside that silver shaft inside the cover that actually hooks to the cable. And when you break that head off, basically nothing happens. Hope that made sence............

 

After reading your post again I saw that you had some tension after you put it back togeather...I don't know, if this pin is broke there won't be any tension at all....Is there any way you can get a pic of your clutch?

 

I can when I take the cover back off, but the pin head didn't break. The clutch does get some tension on it if I adjust both adjusts all the way out.

Its F-ing weird. After the crash BAM No tension, like there was all freeplay. I can't believe that the cable streched that much.

After the pin is in does it move in and out intil it hits against the bearing and pressure plate or should it be tight with no movement after you put the pressure plate on? Something else also is that on the pin there seems to be a flat edge, why?

 

Pin should be completely round. Sure it's not broke? And yea it should move in and out a little bit. when you pull in the clutch does it move the lever (coming out of the clutch cover). as much as it looks like it should? Dunno man just trying to throw out some ideas.

 

Yes, Even with NO clutch tension when I would pull in the clutch, it would move the lever on the clutch cover, but it would move it as if the pin was just pulling out until the very end then I could feel just a hair of tension. That when I adjusted both adjusters to the max and acually got tension on the clutch. But, there is no way I should have to adjust them that much. Maybe could the clutch cover be bent in just a little or something?

Besides this strange problem jsut to make sure the clutch is together correct I have two questions. First, the judder spring. Its concaved, does it get put in with the cone facing in our facing out? And, the last friction disc. That one goes in the short slot, opposite of all the other ones. So it is all by itself. Correct?