Motorcycle Repair: manual clutch 2003 honda xr50, manual clutch, clutch adjustment

Question
i recently installed a manual clutch  on my 2003 xr 50 from Trailbikes. Everything went together smoothly but when i started it up to ride and pulled the clutch lever in, the clutch does not disengage and the bike stalls out when i go to put it in gear. I have played around with the  clutch adjustment skrew under the cover plate, but it was no help, what could the problem be? I have had the skrew al the way out  and in on adjustment and it does the same thing - stall out. Second question is - how does this clutch suppose to work, if I could understand how it is suppose to disengage I could prolly understand  the problem. thanx - mike

Answer
Hi Mike.

To be honest, I am not sure where to begin with what could be wrong.  There are any number of things.

As far as the clutch, what it does is engages and disengages, using a series of friction plates to couple the engine to the drivetrain, thus allowing the power to be transferred to the rear wheel from the engine.

Now you could have an internal piece in wrong, or the actuator could be in the wrong position.  You could even have the wrong cable or a misadjustment at the lever on the engine.  If it is in the wrong position, then that could be the crux of the problem.  Refer to the repair manual for correct positioning of that lever, but you should not have a huge amount of slack in that cable.

Let me know what you find.

Good luck and ride safe.
FALCON