Clutch issues...

[JustinLonghorn]

I pulled the sprocket cover off to polish it. When I put everything back together, I made sure everything went back the same way it came apart (including the D-ring with the three ball bearings). My clutch lever is able to be pulled in all the way and snaps back with no problems. The bike will shift with no issues (when the bike isn't running). When I start the bike, pull in the lever and pop it into first, it is as if the clutch isn't working at all.

Any suggestions?

 

[crazypj]

Two things,
first, adjust the operating mechanism after loosening off cable then re-adjust cable
second, 'stiction'
oil is sticking clutch plates together.
Either kick bike over with clutch in before starting or put in gear, pull in clutch and 'rock' it backwards so it opens fully before starting engine

 

[VonYinzer]

yup, what he said...

 

[JustinLonghorn]

Alright, so I tried the factory suggested adjusting method (loosen cable, turn adjustment screw counterclockwise until you feel resistance, turn it 1/4 turn clockwise, adjust cable) to no avail. I also tried kicking it over in gear before starting... nothing.

Any other suggestions?

 

[mixmaster]

Tihgten the adjustment to take all the slack out of the handle and see if that cures you'r problem. If so the plates are sticking. Is the oil for a wet clutch, that is if you have a wet clutch. You can even take a short ride with the adjustment like this.(not so tight you can not accelerate with out slippage) The plates should start slpiing With this lil yse. Then adjust for clearence and test ride again. Most bike clutches that hang up,if not worn or miss adjusted do not have the proper oil on them..

 

[old honda 350]

In the spring, I tie the clutch lever to the handlebar over night to get past the stiction. Clutch works fine after that.

 

[JustinLonghorn]

So, I got this thing figured out...

Last week I had my bike in the shop for a "safety inspection." As I said in my build thread, this was my first build. I used the factory manual for all of my reassembling duties. The shop checked everything I asked them too, did some quick maintenance (bled the front brake, adjusted the rear brake, etc), and tried to do a test ride. Where he quickly found out the clutch wouldn't disengage. He took the sprocket cover off and reassembled the clutch actuator according to the same Factory Honda Manual that I had used. Here is the picture from that Manual:

After many times disassembling and reassembling this thing by the shop and then by me, I did some internet research and found this picture:

The factory Honda Manual was incorrect. I have no clue what manual the second picture came from, but I am definitely glad I found it.