Clutch Help Please!

Hi Guys,

I have been creeping around this forum trying to work out whats wrong with my clutch. Ive seen loads of detailed threads but none of them seem to address my problem.
My clutch is SUPER stiff. I know the clutch arm is supposed to be stiff when you try to move it with your hand but mine wont even engage with the lever. I have pulled the cable as tight as it can go but now the clutch lever on the handle bar cant even pull it.
I got so mad i even took a hammer to the clutch arm to see if it would move but nothing!

I took the cover off, took the pin out and the ball bearing is there.
I took the right side cover off and tried adjusting the "flower nut" but that seems to be stuck on and wont budge.

Does anyone know of another way to test/check the clutch. Or how to get the flower nut unstuck? Mine looks like its not supposed to move!

Please help???!!!!

dont use a hammer on clutch arm.

yea i no, i knew it was a bad idea at the time but i didnt hit it that hard to be honest. just tapped it to see if it would move. I cant see how the cable would be strong enough to move it. Theres got to be something restricting it from inside, i just dont know what.

I thought maybe if I took it all appart I might be able to work it out. I recall one guy saying he took his appart and found that it had been assembled incorrectly at manufacture.
I cant take mine appart as the flower nut seems to be welded on!

The first question I'd ask is; Is this a new engine that has never run? Many guys have trouble with the clutch at first because from manufacture until the time you get it the clutch pucks (friction surfaces) can stick. Usually all it takes to free them is a good hard push on the clutch lever (the one at the engine) I know it seems stiff and hard to move with your hand but it will if you apply enough pressure. I made a tool to move the clutch lever but Vise-Grips will work too. Wrap the lever with a cloth so you don't scratch it all up then rotate it toward the engine using the Vise-Grips as a lever which will put more pressure on it than you can comfortably do with your hand. If the pucks are stuck they will usually free up with this method. It's always recommended to lubricate the clutch cable also. Oil works but if you remove the cable from the sheath you can coat it with a light grease. Good luck, let us know how you do.
Tom

__________________
Age and Treachery Will Always Triumph
Over Youth and Skill

even a small skinny guy like me was able to work the clutch,sure it was hard at first(took my both arms to move it)but it was easier after breakin in and riding a while.
maybe yours is stuck.my clutch lever still working.goodluck.

Hi Tom,

Yep, this is a new engine, never run. I began putting it together about a week ago.

Somehow i managed to get enough pressure out of my thumbs to push against the clutch arm and i can see the clutch plate moving in and out ever so slightly on the other side. Its taking a huge amount of force to get this to move and the bike still will not roll when the arm is pushed in.

The flower nut can now move. I've pulled on the handlebar lever and put in the locked position, tried adjusting the flower nut and this bike still will not roll.

Oh and Cabinfever1977.... would this be a good time to mention that im only a little lady? with very little strength??? lol

you need one of these CLUTCH ACTUATOR

Thanks skjjoe

shimzy,

It is a design flaw...some are worse than others.

Jim

Hi Guys,

Thanks for the link skjjoe.... but it seems as Jim has pointed out that it is a design flaw.
Even if I were to use the clutch actuator, it doesent quite resolve the issue of the bike not rolling.
It might make it easier to pull the clutch but i've been fighting with this clutch for almost 2 days now and like i said, even with the clutch arm pushed in, the bike still will not roll.
Theres got to be something wrong in there.
Does anyone know of any other way to get the bike to roll? Should I take the entire content of the clutch (on the right side) out and start again??? Something must be causing the restriction and i really wanna find it and give it a peice of my mind!

Make sure all moving parts of the clutch and cable/lever are well lubed and have a look at this-
External adjustment of the primary clutch spring

__________________
If it ain't broke, and you mess with it long enough, it will be.