Questionsounds like with your knowledge you will be able to help us. My son was riding the bike last fall and the clutch started to slip so we tried to adjust it but it just kept getting worse. We assumed it was the clutch plates so we replaced them. After we put it back together we can't get the transmission to engage. I don't know what I did wrong. the transmission engaged before we took the clutch apart.
AnswerWalter.... Did you soak the friction plates in oil before installation? Sounds like either a clutch assembly problem or the clutch release system is not disengaging the clutch to allow for gear engagment. If the clutch doesn't have any free play at the lever, then it is not going to engage fully. If the clutch has too much free play at the lever then it won't disengage all the way, which keeps the gears rotating at idle, instead of allowing for engagment of the shift dogs.
From what I see on the on-line microfiche services, it looks like the clutch release items are part of the clutch cover. Check them to see if anything has shifted or broken.
Some of the release cams are on roll pins that can shear. You do have to ensure that the clutch pack was assembled properly, so that the outer clutch pressure plate fits down inside the splines of the clutch hub.
If you had the shift shaft out or loose when the clutch was being replaced, you may have knocked the gearshift spindle out of position, somehow.
Kind of hard for me to judge what kind of work was done, what was worn and what still needs fixing from here, though. Get a good quality shop manual so you can see the parts in exploded views and follow their directions on the inspection and assembly process.
Bill Silver
