Cant adjust clutch?

[lgndryspacemnky]

Hi there, after reading a handful of posts i had concluded that my clutch's pushrod/ball bearing had welded to each other causing my clutch to not work properly. After removing and replacing the damaged parts, in an attempt to achieve proper adjustment of the actuators screw, i discovered that i cant thread the screw in without compressing the springs. Im sure i have everything in place correctly, the only item i have not installed is the drive sprocket cover gasket, this couldnt be the reason i cant adjust the clutch correctly...could it?

[DonTZ125]

The idea is to back the actuator screw OUT until it isn't touching the push rod, then move it in until it just touches, then back out again 1/4 turn. If you can't do that before the actuator screw falls out, something is wrong in your clutch stack.

[lgndryspacemnky]

I will check my clutch's plate configuration again, hopefully im overlooking something.

[lgndryspacemnky]

I'm still having the same problem with the actuator screw, the clutch is in proper order, any other ideas? Should there be resistance when threading the screw in? The ball bearing in the actuator assembly, that is supposed to be there, right? I keep pondering with the possibility that i received the wrong part when i ordered the clutch pieces...

[lgndryspacemnky]

I checked my clutch from the collar on the transmission shaft all the way to the springs, every component that had a max wear limit is within standard according to the service manual. All the pressure plates are arranged so that all the stamped edges are facing in the same direction. The nut is torqued down correctly, as well as the springs. The final pressure plate is in line (the dot and the triangle). I was left to believe the problem with the adjustment screw not threading in correctly into the actuator was due to incorrect re-assembly of the clutch's actuator itself. I inspected the push lever assembly and the adjuster mechanism, nothing seemed out of place compared to the photo in the manual. I think it is the correct piece,i just had installed it incorrectly. I reversed the adjuster mechanism's position so that the longer end is in place into the drive sprocket cover. In doing so, i am able to thread the adjuster screw in and achieve proper play in the clutch lever after i backed the screw 1/4 of a turn. However, I now have the adjuster mechanism not all the way flush with the drive sprocket cover. The two phillips headed screws that hold it in place are not making a firm connection. Any thoughts on a way to remedy this issue? I have installed the clutch in a way that leaves the pushrods and ball bearing to not have constant contact while riding (which is how i ruined the parts to begin with) but with the adjuster mechanism not in its proper position.

[reelrazor]

Anytime I hear/read "everything's right, but it doesn't work" (paraphrasing here-applies to carbs, engine internals and yes, clutches) I have to think on my years of turning wrenches for fun and for profit...

Whenever I have been in that position/mindset I need to start way back at the fundamentals-with NO expectations and start fresh, checking everything.

Now, refresh my memory...why did this start happening? Did you DO something, or did it just start occurring?

[lgndryspacemnky]

I bought the bike from the P.O. who said the clutch needed to be fixed. I didn't replace any of the internals, I instead drove on. It wasn't long before that my pushrods and ball bearing, and actuator welded to each other. The long pushrod broke inside the transmission shaft and it wasn't coming out. I split the cases to remove the transmission. I put everything back together, but i don't think i put the clutch release mechanism in right. The clutch works, but the way i have the adjuster mechanism, its not mounted flush to the drive sprocket cover. I guess what im in need of is a pic of a proper drive sprocket cover with the clutch release mechanism installed.

[Fizzinatorr]

Look through the various clutch re-build threads on here and you should find the pics you need