??? about clutch drag

[jvann13]

I just changed out the shift stopper lever on my 06 yz 125 for the 07 model stopper. I pulled the clutch out to get to it and put the clutch back in. Now the clutch is dragging very badly.

When in neutral it is fine. In gear with the clutch pulled in it is not disengaging at all. I did remove the disks from the basket but left them in a stack so they did not get out of order. I did not see any grooves in the basket like some talk about in past threads. I need some advise for when I pull it back apart. It sounds and feels like it should be working. Could the cable need to be adjusted even though I did nothing to the clutch other than pull it out and put it back in?

Put new oil in also.

[lessthanevan]

Check your pressure plate to see if its been blued due to heat, Also check your steel plates for any warpage, and any notching on your basket or hub. Its a 06 so unless you fan the piss out of your clutch every day then it should be ok.

[jvann13]

Thanks I will check that but I don't think that is the problem. It was perfect before I pulled it out and put it back. I must assume I did something wrong putting it back in. I looked out for the normal errors but this is the first time messing with the clutch and I did nothing more than pull it out and put it back to get at the stopper lever. ? It seemed to be a in and out job.

One other question. The bolt that hold the basket in. Do you bend the stupid tab back every time you put that bolt on or do you use loctite???

[lessthanevan]

yeah your supposed to get a new tab, but if you dont break it then just bend it back. When you re-installed your steel plates (driven plates) did you put them in sharp edge in 1st, away from the pressure plate?

[jvann13]

I would say yes to re-installing them in with the sharp edges in first. I say this because I pulled the entire stack out and put it back in the same way. This was the one thing I made sure about because of the searches I did on TT. I will add it to my check list for when I go back in.

Any thing else I should check??

Thanks for the help.

I will go get a new tab to have on hand for when I go back in.

[rmz757]

just curious, what happens if you put them in rounded edge first?

[lessthanevan]

it will cut up the pressure plate

[rmz757]

how would it cut the pressure plate? there should be a fiber between the pressure plate and the steel plate? Not trying to argue here, i just really dont want to have to open my clutch up again this week hahaha

[jvann13]

So I pulled the clutch back out and everything looked good. Everything looks brand new and everything was in the right place. Put it back together and it still had a bad drag in gear with the clutch pulled in. I could feel the bike lurch a bit if I kicked it in gear.

I pulled the clutch cover and pulled the clutch lever in and it is definitely disengaging. Please help. What could it be??? It was perfect before I pulled it out the first time.?

[RCannon]

It sounds very normal. Ride the bike for a few minutes and see if it is not much better.

Lots of times we pay close attention to a piece we have just worked on. You notice little noises that were always there, but you now pay attention to the component.

Did you set the tension on your cable the same as it was?

I have a full Hinson clutch in my 06. It too drags when cold.

[jvann13]

Thanks RCannon. I never touched the cable. I did not think I needed to. Should I have done something to it?? It seemed to be adjusted correctly the first time and all the subsequent times??

I pulled it apart yet again and everything was still in the same place as the first time I pulled it apart. Everything looked right. It seems simple but I don’t know. I fired it up, let it warm up and gave it a spin like I have every time. I hoped the bad drag would go away. It is still there. If it is in gear and I roll the bike and pull the clutch in and out there is a slight difference. Not as bad when the clutch is in but barely any difference. The engine still turns over rather than the plates spinning.

I even pulled the springs and pressure plate off and rolled the bike and it still drags bad (this should make it have no pressure right???)

Going on my research and limited experience it seems like everything is perfect and the plates are just grabbing. Could it be I put it in wrong the first time and cooked the plates and now they are bad?? I check them and they are not warped or out of spec.

This might be the kicker. This last time I pulled it apart the post on the clutch boss that the springs slide over was scored by the springs. I am not sure how this could happen. Maybe this will shed some light on what I did wrong? Only thing I can think would do that would be the bike slamming in gear going into first. When I put it in first it is snapping into gear hard enough the make it stall if not revved.

I am usually good with this stuff but I am lost. ?

[BRM]

Have to agree with RC there, sounds like you have done everything right. Initually when you re-assemble the clutch the plates will stick together. Warm it up and take it for a spin, it should be ok.

[RCannon]

If the cable has too little tension on it, it might not seperate the plates.

Try adjusting the cable length until you have just asmall amount of slack between the lever and perch.

[jvann13]

Thanks guys. The clutch is disengaging right as you pull in the clutch. No play in it. I let it warm up (about 3-4 min) and rode it around about 2-3 min (shop parking lot – not much room). It was still dragging badly. Is this normal? Do I need to ride it longer to let it loosen up?

[olddude]

I just changed out the shift stopper lever on my 06 yz 125 for the 07 model stopper. I pulled the clutch out to get to it and put the clutch back in. Now the clutch is dragging very badly.

When in neutral it is fine. In gear with the clutch pulled in it is not disengaging at all. I did remove the disks from the basket but left them in a stack so they did not get out of order. I did not see any grooves in the basket like some talk about in past threads. I need some advise for when I pull it back apart. It sounds and feels like it should be working. Could the cable need to be adjusted even though I did nothing to the clutch other than pull it out and put it back in?

Put new oil in also.

Just ride it. When you pull all that stuff apart it takes time to get used to the new position the plates are in. It's like when you put in new fiber and steel plates in, you have to take it out and burn it in to get the clutch to work right.

Also you might check the shift shaft that goes through the motor. It's about 7 inches long and it pushes on the little steel ball that pushes on the thrust bearing. You did put the ball back in there didn't you? anyway, sometimes that shaft will wear or even snap into and cause all sorts of problems. Problems that are related to the detent bearing failure. I would pull all the shift parts out and inspect them for proper wear and position, and if they all look good take it back out in the parking lot and burn it in and it should be ok. Oh, and make sure the cable is properly adjusted before you do anything.?

[BRM]

That should have freed it up, it sounds like it may be an adjustment issue.

Very hard to tell from here.

[SeniorYamahaRider]

You might want to try this the next time you have it apart. Put the bike in 1st gear. Take the pressure plate off and remove the stack. Turn the back tire and watch the clutch basket. If the outter (opps should be inner) basket rotates but the inner (opps should be outer) does not you should be okay. If the inner (opps should be outer) rotates and starts to turn over the engine something is binding. I would inspect the push rod and make sure it is still in one piece.

In addition check the torque of the nut that holds the assembly together. I read here where someone had over tightened this nut and the clutch dragged as you described.

[jvann13]

Thanks for all the help guys. I checked the push rod and ball. They looked fine. And all is in place. I think olddude might be right. I am starting to think a few minutes of riding in a circle in first gear is not enough to get the plates to seat. I will give it hard ride and give the clutch a good workout this weekend. I think this will fix it.

[olddude]

I have the same problem with my 05. But mine is because I have put a extra steel plate in my clutch basket because if I don't I can't seem to get the clutch to hold under a heavy load with the extra plate out.

When they changed the shift assy in 05 they fixed a problem they had with the old shifters but it looks like they have created another problem with the way the new setup works. Exploding shift detent bearings, breaking shift pusher shafts, bending shift levers on the ignition cover side. I replaced every part in the shift assy and I still have to put another steel plate in the basket to make the clutch work.

I wouldn't fuss too much though, if you know it's adjusted correctly and it still sticks that means you have good clutch plates and the bike should really dig. The only other thing I could think that could be a problem would be that the steel plates all or maybe just one or two could be warped and sticking because of this. You can check them with a straight edge. that's streching it a bit but I have seen that happen. And OH, Im sure you have checked this but the clutch basket fingers are not groved are they? I was thinking about this today and these other things came to mind so I thought I would share.

Another thing, for some reason these bikes with the new shift assys don't like to be put in 1st gear especially when you have a new or sticky clutch. I don't know what kind of riding you do but if the problem persists try taking off in second and you should have no problem. We hardly ever use 1st gear and that eliminates the chance of a mis-shift to nutral when going up through the gears. ?

[jvann13]

Thanks olddude. I have checked everything out at least 3 times. After pulling my bike apart 6 times in the past few days I have come to the conclusion that I am now over thinking this (I can be anal about little things). Every thing is perfect and very close to new as far as tolerances are concerned. I have spent a lot of time changing out a $10 part that should have taken less than an hour. ? This reminds me of when I changed my front pads on my street bike. They grabbed real bad and it bothered the heck out of me. It seemed like it took a life time for them to seat.

Well at least when I have to replace my clutch, I will be able to do it with my eyes closed.