My bike, it no movey movey.....

[shigs]

So I replaced my clutch pushrods, ball, and seal.....got the bike with a broken long pushrod and the both of them wleded to the ball. Clutch pulls just fine, shifter clicks through all of the gears.....but the bike won't move, just sits in neutral. Any ideas?

[ragedigital]

Put the chain back on... j/k

Well, it sounds like even though the clutch is pulling, it might not be disengaging properly. It might be that the shift drum is not rotating. You're going to have to tear back into it. Keep your Service Manual handy during re-installation.

The real problem is that we can guess all day long, but you may have to have someone close by take a look and give a second opinion.

[shigs]

How would I figure out if the shift drum is rotating? I have a Chilton manual, but I find that it doesn't go very deep into every detail or cover all issues. Sometimes its better to pop in here and get the info from someone that has some hands on knowledge.....

[ragedigital]

How would I figure out if the shift drum is rotating?

You can see it rotate with the clutch cover off. The shift drum moves the shift forks.

viewtopic.php?f=8&t=206

[reelrazor]

Umm, make SURE that the clutch pressure plate is on correctly.

There is only ONE way (out of five possible) that the pressure plate can be PROPERLY placed.

There is an arrow on the end of the inner hub (on one of the proud splines), and a small hole on the pressure plate. these need to be aligned to each other. If not, you end up with YOUR symptoms.

This is an old Yamaha thing...they did this way back in the seventies.


Make sure you back off the clutch pushrod adjustment...as it will be adjusted waaaay too far in if you set it with the pressure plate installed wrong.

[shigs]

That's the outer plate that gets screwed in that the short pushrod backs up against? If that's the case you might be right. I just picked that up off of the workbench and put it on however it fit in. I'll pull the cover off today and see....

[shigs]

My clutch handle is super tough now too so I think you're onto something

[ragedigital]

I just picked that up off of the workbench and put it on however it fit in.

Please, get a Genuine Yamaha Service Manual and use it. I'm sounding like a broken record.

They will instruct you on all of that. My Kawasaki 4-wheeler is the same way in that you have to line items up the clutch as well as many gears in a certain fashion.

[shigs]

I understand all of the manual hype but they don't lay it out like SYMPTOM-POSSIBLE CAUSES-CHECK THESE FIRST. the manuals are more THIS IS HOW IT COMES APART-THIS IS HOW IT GOES BACK TOGETHER

[ragedigital]

I understand all of the manual hype but they don't lay it out like SYMPTOM-POSSIBLE CAUSES-CHECK THESE FIRST.

Actually... they do (see TROUBLESHOOTING). However; they rarely state "Hey, you probably installed it wrong". They usually point to a worn out part. They expect you to put it back together correctly.

I'm not trying to beat on you, Shigs, but you seem to be your own worst enemy.

[reelrazor]

My clutch handle is super tough now too so I think you're onto something

I KNOW I am on to something.


You can see (with your EYES) that the pressure plate is NOT flat against the outermost plate when it goes on incorrectly. Gotta keep them open tho...

[shigs]

Well I lined up the pressure plate so it fit perfectly into the grooves.....made my clutch handle less tough and seemed to work correctly. But after putting it all back together....pretty much the same thing. it will click into gear, and you can feel the bike get into gear with a little bump, but rev the gas and it goes nowhere. After several attempts, sometimes it will only go into second and nothing else. When the bike is off, it rolls freely in every gear. Any ideas?

[shigs]

My clutch handle is super tough now too so I think you're onto something

I KNOW I am on to something.


You can see (with your EYES) that the pressure plate is NOT flat against the outermost plate when it goes on incorrectly. Gotta keep them open tho...

So do the grooves on the pressure plate go into the grooves on the last plate? There is no arrow or markings to show me. And the manual doesn't cover this is detail....

[reelrazor]

Well I lined up the pressure plate so it fit perfectly into the grooves.....made my clutch handle less tough and seemed to work correctly. But after putting it all back together....pretty much the same thing. it will click into gear, and you can feel the bike get into gear with a little bump, but rev the gas and

You need to back off the lower clutch adjuster (by the countershaft sprocket) all the way...turn it in until it makes contact and then back it out a quarter turn and lock the jam nut.

If the clutch still slips (and it IS slipping or you wouldn't feel the "bump" when it goes into gear), then you need to take it back apart and see what else you installed incorrectly.

[sweekster]

So are you doing all this without a manual? I suggest getting one if you are. It may actually help you achieve your desired result.