Alright so I finally got around to getting this thing back together and the engine seems to run well so far...
Only my problem now is my clutch... heres the story: Before I rebuilt the top end, the clutch was dragging/sticking pretty bad (this was the oem
stock clutch). So I pulled it apart and inspected everything, all the fibers on the stack still look healthy compared to the pictures I've seen? Nothing looks excessively worn and there isn't any real knotching on the basket, you can see marks where the stack was but if you feel, you can hardly discern a difference.
I figured I would try to replace it with a cheap clutch pack to see if that would fix my problem and if it didn't I wouldn't be out too much money and I could continue troubleshooting. (I would've just replaced with OEM
right there if the plates or assembly looked like it was actually worn.) But since I had doubts that this was actually the problem I went ahead and ordered a Tusk
stack. So I received the tusk
stack and promptly dipped all the plates individually in oil and rubbed it around on them until they each seemed saturated. (I'm thinking maybe I should have let them soak?) I installed them the same way my OEM stack was installed (with the slightly thinner plate on the most inside of the basket.
I checked the pushrod and it seemed ok and like I wasn't missing any pieces of the assembly according to the parts diagram.http://www.bikebandi...a/YA5986_25.gif
I did notice however that you could pull on the basket and you could pull it away from the engine maybe a few millimeters and also push it back the same amount, I wonder if this play is a bad sign??? I torqued the spring bolts to spec (I installed the tusk clutch springs which feel like the same stiffness as oem). I pulled the clutch lever
before I put the cover on and I notice that the stack doesnt really move that much even when the clutch lever is all the way in and I even set the cable excessively tight to see if it would make a difference, not really.
So I return the cable to proper settings and put the cover back on, I start the bike and let it warm up at idle for a few minutes. I hop on and shift to first whilst having the clutch pulled and and bam I peel out of my garage and down the driveway I go. Basiclaly I shifted into first as if I didn't have the clutch pulled at all. I tried driving it around and reving it with the clutch in but it wouldn't ever let go like the plates are stuck together. Also the clutch pull feels really weird, I don't remember what exaclty it felt like before since its been so long but there is literally no feel at all to it like I am pulling in the brakes on a bicycle or something. It feels especially weird when comparing it to the feel of my wifes quad and my friends bike which both also have cable clutches.
Any suggestions on what I should do next? Is it possible that the plates could be THAT stuck to each other? Could laying it on its right side for a while help anything?
EDIT: I have since laid the bike on its clutch side to let the plates soak for about an hour, drove it, still did the same thing.
After that I swapped back in my old clutch, still does the same thing. I also compared the height of the stacks, they are almost exactly the same, you cant discern a difference with the eye, only with calipers.
I feel like maybe I am somehow assembling it wrong?? Just to make sure, the ONE plate that is slightly smaller than the others goes into the basket FIRST right? Well shit, the parts diagram actually shows the smaller single plate on the outside, shit, guess I got the stack in backwards.
I might sleep on it and see if I can think of anything if flipping the stack doesnt work.
EDIT 2: well my dumb ass put the stack in backwards >.> <.<
So yeah now it works!
Edited by fdme, January 08, 2015 - 02:53 PM.