Clutch issues

[bennyboom]

So im new to the forum. Just bought a wrecked blast from a buddy, its only got a touch over 3000 miles on it. Its been sitting for a year and half. Cleaned the fuel system out and it runs now. The problem im running into is the clutch wont engage. i did an adjustment because the lever was really loose and still no dice. Any suggestions on what my next move is? Thanks in advance for any help.

 

[konarider94]

do you mean disengage?

 

[bennyboom]

Yeah sure.

 

[konarider94]

what happens? so you start it in neutral and when you click it into first it lurks forward and stalls with the clutch lever pulled in? you havent really described what it happening.

 

[bennyboom]

I start the bike in neutral and with the clutch lever pulled it grinds. I hav ent actually shifted yet. And with bike off and in gear squeezing clutch lever also does nothing.

 

[konarider94]

it shouldnt be making any noise in neutral. take the clutch cover off and take a look in there. maybe post a picture. take the ramp out too. and take a look around.

 

[bennyboom]

Well it doesn't make a noise when in neutral it grinds when attempting to shift. The clutch lever is tight but it doesn't seem to disengage the clutch. I am pulling it apart this weekend.

 

[konarider94]

There is also and adjustment behind the clutch inspection cover. Turn cc until it bottoms the turn clockwise 1/4 to 1/2 turn. Also check for a broken lip in the cover behind the ramp assembly.

 

[jetlee]

There is also and adjustment behind the clutch inspection cover.  Turn cc until it bottoms the turn clockwise 1/4 to 1/2 turn. 

DO NOT BOTTOM IT!!! Common mistake that ends up with a clutch never fully engaging, if at all.

Loosen clutch cable first at the adjuster, then:

The adjustment screw should be loose. Turn it CCW (Counter ClockWise) until you feel it tension against something. STOP TURNING IT!!!

Now turn it CW (ClockWise) 1/4-1/3 turn (until you can fit the hex keeper back on, no more than 1/3 turn).

Tighten clutch cable at adjuster until there is only 1/8" of slack at the handle. Pull/Release the handle several times with the engine idling in neutral and re-adjust cable as necessary to maintain 1/8" play in lever.

 

[konarider94]

 

[jetlee]

Thank you for posting that. I know the manual uses the term "lightly bottoms", but I've spent a lot of time where guys turned that screw well beyond that point and really bottomed it out resulting in a slipping clutch.

I've found it better to describe it as:
Unscrew till its floppy, then screw it in till you feel it hit something that causes tension.unscrew 1/4 turn from there and you're done.

 

[bennyboom]

Pulled the cover and no broken lip. I'm not sure what I'm looking for but nothing stands out as damaged. I also can't seem to get a hold of a manual. It is an 03

 

[konarider94]

idk what to tell you. maybe attempt to take a video. i assume you adjusted everything right and tried it again. are you familiar with motorcycles or is this your first one?

 

[bennyboom]

My first bike but no stranger to wrenching. I still have inspection cover off. I guess I'll get a video of it and see what you guys think

 

[bennyboom]

Would my primary being to tight have any effect on clutch movement?

 

[konarider94]

have you tried to just kick it in, not hard enough to break the shifter or anything but its usually a quick movement. you arent trying to push it into gear slowly are you? pull the clutch in and kick it into gear. it will either stall or shift into first successfully.

 

[konarider94]

I still have inspection cover off

so you havent put it back together and tried the adjustment inside the cover? adjust it based on the above directions and give it a try

 

[bennyboom]

Alright so clutch is fully operational. My problem was the part where the cable connects was pulled forward. I followed all your directions plus sliding that back as far as it would go. I took my first ride on the bike and I'm a little impressed. I was expecting a little worse performance as it sat for a year and a half. Thanks guys. And it seems the bike won't idle with kickstand extended. Is this normal with the blast ?