Clutch Lever Free Play Question

Energy One

Rich_M

Member
This is probably elementary but I recently adjusted my clutch. I did the following:
  1. Torqued the clutch hub shoulder bolts to 30 in-lb​
  2. Adjusted the adjustment screw till gently seated and backed it off 1/2 turn.​
  3. Locked it down with the lock nut while holding the adjustment screw in place with an allen key.​
I did all this with the clutch lever slacked out. Now when I adjust it, I can see the lever tightening up, but it won’t go tight enough to actually engage the clutch. I must have missed something, but I don’t know where I went wrong. I have braided steel cables. Any ideas?
 

Rich_M

Member
Still on the struggle bus. My clutch handle is 100% flop now. The first pic (the one with less threads showing) is prior to my other thread about snapping the adjuster screw. Before I messed with anything. This second one is after taking plate off and removing the snapped bolt and replacing the screw. That looks like a pretty big diff to me. Is it possible I damaged the diaphragm spring? I really can’t even get any tension on the clutch handle, even with the cable adjusted all the way out. I wanted to check the community before I ordered new parts. I am also thinking of bending the lock tabs back out and rechecking the torque on the shoulder bolts, even though I was pretty darn careful to make sure they were torqued to 30 in-lbs. I’m hoping that this is a “dummy, you’re doing it wrong”-situation. Thanks for all your help you guys have been great.
 

Attachments

Rich_M

Member
One additional thing. My initial test ride had a fairly normal feel, but friction zone was the clutch all way out. Then I adjusted it again and it was “walking” with the clutch in. Then I was doing a 3rd adjustment and I loosened the cable all the way out to where the two parts of the cable adjuster basically separated. I threaded them back together, but I haven’t been able to get tension in the handle since.
 

Chong

U-235
I would be checking tightness of the nut that clamps the clutch basket to the trans shaft. The one behind the pressure plate .. Could be loose letting the clutch move laterally and canceling adjustments made. I've had three things occur on the clutch. Cast eyelet up at the lever fail on the cable. Outer cable housing failure (may have been caused by not tubing a new cable) and that nut being loose .. Its LH thread , red loctite, 80 ft lbs . Some go higher on the 05 and up which not everyone recommends.
 
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Rich_M

Member
I would be checking tightness of the nut that clamps the clutch basket to the trans shaft. The one behind the pressure plate .. Could be loose letting the clutch move laterally and canceling adjustments made. I've had three things occur on the clutch. Cast eyelet up at the lever fail on the cable. Outer cable housing failure (may have been caused by not tubing a new cable) and that nut being loose .. Its LH thread , red loctite, 80 ft lbs . Some go higher on the 05 and up which not everyone recommends.
There’s a small plastic insert in the handle that has an eyelet in that looks like it supposed to accept one of the barrels. But there isn’t anything seated there is that correct? That would explain a lot, if correct.
 

Rich_M

Member
Sometimes I over communicate about stuff. I was thinking that barrel might go in there. But think I was mistaken. I’ve took it apart and I couldn’t get at where the cable is secured to the handle. I know it’s still attached at the lever, because I can pull it back and forth but it feels like it might be loose at the pivot. Anyway, I’m going to go back to the clutches hub, disassemble and reassemble the hub, checking back bolt, plate order, and torque values, close it and call it good. I’ll return to the cable if that doesn’t fix it.
 

HMAN

I just like my Freedom
Supporting Member
 

Rich_M

Member

Sven

Well-Known Member
The wave plate should be flat. Say it's concaved: this says the plates are worn out, the clutch center moves into the clutch outer: meaning, the frictions thin out and the wave plate goes from flat to almost concave. So no the clutch center does not move, but the plates move into the clutch out. Instead of the coiled springs, the wave acts like a spring. In other words, the more concaved, the more the wave trying to go flat, the less tension, the less throw, meaning, the concaved takes up the throw trying to break the plates apart.

Cheap fix is to shim it with a steel plate next to a steel plate: moving the wave plate flatter. The right fix is to change out the clutch pack with all new so the stack is back to said thickness, the wave plate shows it goes flat.

So it's a 1/4 turns out from a lightly seated start, turn the cable adjust so there is almost no slack at the lever's gap.
 
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Rich_M

Member
VERY happy to give this update. I have figured out my cable slack issue. Basically, not being able to get any tension can have a few causes. 1.) You could have a stretched or broken cable, 2.) Something could have broken in the lever itself, or 3.) Your ball and ramp assembly that attaches to the clutch cable under the transmission side cover can get stuck on the bearings, if they ride up out of the little divots that they slide up and down in. For me, it was number 3. I drained the transmission and took the cover off and removed the snap ring, took apart the little bearings and ramps assembly, put grease on the bearings and put it all back together and reinstalled everything.

Now my clutch is very firm with very little cable played out. Neutral is super-easy to drop into, and I am working through the normal clutch adjustment experimentation to get everything dialed in. Then torquing and loctite-ing everything down.

I am probably going to revisit the throwout bearing and install the Baker Heavy Duty Throwout Bearing Kit into it. After that. hopefully will not have to look at it for a long time. I learned a lot about clutches in general and Rivera Pro clutches in particular and it was totally worth the time.

Thanks for everyone's help! What a supportive and kickass community of chopper maniacs we have here! Grateful!
 
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