help! clutch problems help!

[kevinkline]

I have a 1985 200x i just rebuilt the clutch in and when i put the engine in the frame for final assembly it has no feel to the clutch. I dont think the mechanism the pushes in the clutch is working because its doenst disengage the clutch and i rebuilt the clutch to how the manuel told me to oil plates and then put em in and i put new versah clutch plates and heavy duty springs in it. Could this problem be because i didnt replace the steel friction plates ? my clymer manuel says that it could be the mechanism or becasue i didnt replace the friction plates causing the problem but if you have any idea of the problem please tell me

[Doc86R]

When you say the clutch has no feel - do you mean that the clutch feels solid(no movement) or loose (way too easy to pull the clutch lever)? I'm going off my Rs, but if it is way too easy that means to me the little ball at the end of the pushrod could have got left out. If it is way to hard could be a kink in the cable, can you move the clutch arm at the engine with a pair of channel locks?

X owners chime in, I'm just trying to get the ball rolling here. It's obvious now, but in the future always check the clutch movement before you put the cover back on.

[kevinkline]

i mean that it is way to easy to move and you can move it at the case with your hands it has no feel it just moves and springs back thanx so for tho

[Liquid-Darkness]

A tip when having to pull the case cover off and on over and over before the gasket seals, you might want to spray some of that antisieze copper gasket spray.
Yeah the clutch arm on the case should be able to move with some plyers. Make sure you tourqed the springs right. I know when I put my side cover on my old 200x, I had to pull on the clutch arm a little bit to get the cover to go on. You should probably take off your case side, drain the oil first, and inspect everything. Also make sure your clutch cable is working %100 and there is not too much play. Make sure when you put the bolts on the side cover to be easy on them, I broke a bolt real easy on my 200x while doing that. You should use a small ratchet and only tighten semi snug.

[kevinkline]

my clutch cable is brand new honda cable and i have a brand new clutch lever but that is not the problem the problem is the clutch arm that disengages the clutch has only the resistanc of the spring and i still need to kno whats wrong

[Doc86R]

Sounds like something got left out of yours and the force is not being applied to the pressure plate. You're gonna have to take it back apart and work through the mechanism to see where it went wrong. Find a parts diagram (partsfish, servicehonda, etc) and make sure you put all the parts back in the proper place and test it before you put the cover back on.

[Glenn]

Did you try adjusting the cable at the lever and the adjuster near the engine?

[Troll]

Did you try adjusting the cable at the lever and the adjuster near the engine?


Glenn:hail: ...................................:thumbsup:

[kevinkline]

yes the mechanism moves fully in the case but no feel to it except the return spring i adjusted everything on the lever and engine i could and could anyone send me a link for the diagram because bikebandit doesnt have a good one and my clymer maneal has nothing at all for a diagram

[Glenn]

Glenn:hail: ...................................:thumbsup:

It's often overlooked because it's hiding under the jug. :)

[Travis712]

It's often overlooked because it's hiding under the jug. :)


I thought someone who just put a new clutch in there 1985 200x here..http://www.3wheeler.org/vb/showthread.php?t=23752
could help a little more:chuckle:

[bman200x]

you probably forgot this little thingy (circled in red)
http://i27.photobucket.com/albums/c151/bman200x/untitled.jpg