Clutch Problems live and learn I guess !

[wildfire71]

So I order new friction discs and clutch plates as the clutch slip was getting pretty bad on my shadow the other night while in higher gears on hiway. Parts in today. Decided I will do after work. Clymer manual out to the clutch section and away I go.  Oil drained , footpeg off , clutch cover removed everything easily coming apart following along with manual for re-assurance. Old plates and disc out and new ones put in put everything back together and all is going surprisingly well. So put new oil in and ready to fire up. Done that was easy......(now this is when things stop going well !!
Key in flashed it up and something sounded not right shut down right away.Clutch lever will not go in all the way stops about halfway and bike can be moved while in gear like clutch engaged. So as far as I can tell from a little reading/research is the clutch outer housing came out of mesh with the pins on the oil pump drive sprocket at some point during my attempted repair and to fix this the engine will have to be removed from frame and the right hand crank case cover removed to properly align these parts again. Hopefully I didnt damage anything else in the process. Now I am depressed and need to clear head before I decide where to go from here. I know it wont be "for a ride" Deep breaths !!!

Any advice appreciated.

[MaximX]

The only advice I can give is in moral support as I have never changed a clutch yet.  You are doing good to take a step back and clear your head.  It is depressing to think that so much more work will be required to get it together correctly....one step at a time.  Perhaps talk to a mechanic and make sure of what needs to be done now that you are at this point. Sometimes mechanics have ways to get around some things that manuals say you have to do.  I thank you for this post, if I ever have to do something like this I will try to remember to be very careful.
Mike

[Hans]

Yup, step back, clear head.  I had a similar problem when I replaced my clutch on the my FJ1200.  Turns out I completely brainfaded and put in 2 steel disks side by each.  In the end, an easy fix, but could have easily been avoided.

[Dennis]

Deep Breath.  If something fell out of alignment taking it off, you should be able to re-align putting it back without having to do any more disassembly than done in the first place. 

Have a long stare, think and think again.

I plan on being in the garage tonight after the Ride for Dad meeting.  Maybe I'll walk over and have a look.

Peace & Grease, Dennis

[wildfire71]

Thanks all. I will pull it apart and look again tonight with fresh mind. The Clymer manual is where i found the warning of the possibility of it coming un-meshed. I wish they would of led off instructions with that warning and I would of paid more attention to it during the process. Will keep you posted thanks again boys....sounds good Dennis maybe talk at ya later then ...cheers,

[fast1]

  Read instructions fully before beginning. Soak friction plates in oil for about an hour before installing. Your clutch hub parts fit different ways but only one is the right one. Pre fit them off the bike and mark the pieces for proper alignment. You will see what I mean. As far as the oil pump gear goes it doesn't need to be timed., just aligned. If you are unsure as to which part goes where go to bikebandit.com and view the factory schematic. Engine removal should not be necessary. CHEERS.

[wildfire71]

Pulled apart tonight to investigate. Determined that everything was lined up as it should be clutch outer was perfectly inline with crank gear I put clutch back together as per diagram in manual and everything went smoothly in place once again. With bike on centre stand I move the crank with socket and outer clutch moves as it should i then move the back tire and inner clutch moves as it should. Take off centre stand with wheels on ground and bike is in gear. Acts as if the clutch is engaged. Bike moves freely with little resistance. Took pressure off of clutch at slave and the handle released when I push clutch handle with bleeder closed it goes rock hard about half way in and if you put pressure on lever you can see the slave moving. I am wondering now if it something with the clutch rod from slave through to clutch side. Maybe not lined up at back of slave. Will pull slave tomorrow and have a look as I had enough tonight. Thanks again all.

[wildfire71]

I think I figured it out. Will explain later. Have to get oil ASAP !

[wildfire71]

So the short version is slave cylinder piston pushed out to maximum distance when I took the clutch apart and removed shaft as I did not release hydraulic pressure at slave or master. I took apart used clutch rod to push piston back in .....cleaned up everything put back together ....new clutch fluid and bled system. Through some oil in the bike and fired up and I am happy to say she is rolling along with all the horse power going to wheel rather than clutch slipping. Thanks for the advice guys a few beer and a good long stare at it did the trick !

[MaximX]

Well done.  Glad you figured it out.  A thing that I did not know could happen, and now do by your sharing the experience.