Motorcycle Repair: Clutch problem? Master/Slave??, clutch pack, clutch springs

Question
Rich,

1985 Honda Shadow VTC1100

Been following a lot of posts, bought the manuals, asked questions, researched.  I am not a mechanic....but follow directions fairly well....

Got the Shadow.  Pulled out and cleaned all the clutch plates (as you stated somewhere, they were all stuck together).  Rebuilt the Master clutch Cylinder (new seals, parts etc).  Rebuild the Slave Cylinder.  Bled the line (a lot!).  Bought a Mityvac kit to help bleed, after reading about how miserable the shadows can be.  

So today, bled the line.  Got no bubbles coming out.  Yeah!  Now i have incredible tension on the clutch handle.  Cant really squeeze it in more than an inch or so.  When i crack the bleeder, fluid (dot 4) comes out, no air, handle goes all the way to the grip.  Tighten the bleeder, squeeze 2 or 3 times, clutch handle goes back to barely moving an inch or so.  

with the bike on the center stand, i start in in Neutral.  Kick it inot gear, rear tire spins.  Shift up, tire spins, pull in the clutch lever (only an inch or so) and keep it squeezed in, the tire still spins (fast)...im fairly sure the clutch is not engaging (or is it called disengaging at this point??)

What have i done wrong?  did i put the plates back wrong?  or the Slave cylinder?  Trying to piece it out in my head and draw it out.  Squeeze the handle, slave piston moves out (saw this on the cylinder when i had it  apart).  Cant figure it out.  

Both manuals are not much help....i need an expert opinion, and sorry, i'm not that mechanically smart....

what are your thoughts??

thanks so much in advance,

jeff


Answer
Jeff, it sounds like the clutch pack isn't assembled right.  You need to take the side cover back off and figure out what's preventing the clutch from compressing.  What's happening its that the clutch springs or belville washer isn't applying pressure on the clutch to compress the whole stack together. The clutch level is trying to unload a clutch that fully unloaded so it can't move anything but it's putting tremendous load on the clutch parts so you could break something if you don't figure out what's wrong.

Regards
Rich