Iron clutch/trans

[Mutt]

I've adjusted the clutch step by step by the service manual. Nothing changes

[hayleyl]

Hello Mutt - strange indeed. As Tom said, make sure your 'balls are in the right position. (not the ones in your jeans - I'm assuming Mutt is male) the ones in the ramp. It sounds as if the drive plates / clutch plates are fouling or binding on the clutch hub or clutch sprocket assembly? - I've attached a diagram - are all these parts accounted for and in the right position? Cheers Hayley.

[sportsterpaul]

Wow. pretty mysterious. Applying a wet clutch pushes in on the trapdoor bearing. If it has side play, or of the inside snap ring missing or scwacked, when you pull the clutch the whole clutch gear may be getting pushed in towards the tranny. If you are using a real clutch tool you should see this movement. If you are using a Taiwan puller hooked on the clutch basket you won't.

[Mutt]

Tom, I've adjusted the clutch exactly the way you describe, a few times. Still the clutch is not pushing far enough to release all the plates. The tension on the hand lever feels just like it should and releases like it should

[Mutt]

No. That was tried a day or so ago. We pulled the clutch plate assembly, so the clutch hub was free to spin. Put in gear with the rear wheel lifted up, in all 4 gears, if ya turned the clutch hub, the rear wheel would spin. In neutral, spin the hub and the rear wheel doesn't turn, clutch hub free spins. This it what it's supposed to do.
When ya put every thing back together, adjust the clutch by the book, start the motor and try to shift into gear, it makes a clattering sound, just like as if you were trying to engage a gear without pulling in the clutch lever

[Mutt]

I will check the #8 bearing next time I yank the cover off

[hayleyl]

Hello Mutt - Are all parts genuine or aftermarket? Are all parts from the same year group?. Do drive rings and clutch plates move freely on the hub etc. with no pressure? Cheers Hayley

[Mutt]

everything but the clutch plates are original. yes, all slide freely

[sportsterpaul]

Do toss the steels on a surface plate or piece of glass to make sure they are flat. Dead flat. If they all are warped 0.010, the whole stock will be 70 thou and your clutch will never release. Keep the faith, you will get this.

[Mutt]

i'll check that, but I don't think it's likely. I can't let this bike leave my shop unless it gets fixed. Otherwise I have 40 hours of piddling with it and I can't charge him for it, because it ain't fixed.
Never seen such a tempremental clutch....