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Author Topic: Cannot adjust clutch on AVL  (Read 2112 times)

baird4444

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Re: Cannot adjust clutch on AVL
« Reply #60 on: February 18, 2014, 01:24:24 AM »
another thing to remember when you put it all back together. A chain that is to tight or to loose can make shifting a bitch, almost like your clutch isn't right...
           - Mike
"You can't drink all day if you don't start in the morning!! "
        -Cody Baird
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 but tomorrow I shall be sober and you will still be ugly'
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Arizoni

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Re: Cannot adjust clutch on AVL
« Reply #61 on: February 18, 2014, 04:29:54 AM »
I've seen kerosene for sale in quart bottles for use in old fashioned kerosene lamps.

Of course many of them are scented and they want more for them than two gallons of gasoline would cost.
Jim
2011 G5 Deluxe
1999 Miata 10th Anniversary

boggy

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Re: Cannot adjust clutch on AVL
« Reply #62 on: February 18, 2014, 10:25:09 PM »
another thing to remember when you put it all back together. A chain that is to tight or to loose can make shifting a bitch, almost like your clutch isn't right...
           - Mike

I did NOT know that - Thanks for the heads up.  I will check.

Yeah I thought I've seen small bottles of kerosene for zippo lighter refills.  I'll grab some brake cleaner from the auto store.  Easy enough.

Thanks.
2007 AVL
2006 DRZ400SM

Arizoni

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Re: Cannot adjust clutch on AVL
« Reply #63 on: February 19, 2014, 05:20:17 AM »
For what it's worth, Zippo lighters use Naphtha or white gas for their fluid.
I was talking about the old fashioned kerosene lamps with the glass globe or the lanterns like the old railroads used.

I'm not going to suggest that anyone do this but back when I was a young kid, my buddies and I usually used gasoline in a steel pan to clean parts. Obviously more dangerous than kerosene but it works.

If you use disk brake cleaner be sure to apply some oil to any steel parts as soon as their cleaned.

Kerosene, coal oil, or gasoline (petrol) will thin any oil that's on the plates but it won't totally destroy the oils ability to protect steel parts from oxidation.
Disk brake cleaner on the other hand will totally destroy any oil it contacts so the parts will need to be re-oiled to protect them.

Jim
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boggy

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Re: Cannot adjust clutch on AVL
« Reply #64 on: May 06, 2014, 11:23:20 PM »
Haven't touched my AVL since I got my DRZ - Having too much fun riding a working motorcycle.

I was holding off on new clutch plates because my moto-funds are dry so I figured I'd clean the existing plates and see if they were just gunked up.  Got them nice and shiny and reinstalled. Tightened, then backed off the center screw in the adjustment nut 1/8 of a turn.  No luck, that back wheel spins and spins in gear.  If I apply rear brake it stalls (wheel is up on center stand). 

So that is drag, correct?  Would you expect more or less drag winding that screw out more?

The plates, I'm sure, are bent.
2007 AVL
2006 DRZ400SM

Blltrdr

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Re: Cannot adjust clutch on AVL
« Reply #65 on: May 07, 2014, 04:08:14 AM »
You have to slack of the adjusters before the adjustment. Afterward readjust the cable.
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boggy

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Re: Cannot adjust clutch on AVL
« Reply #66 on: May 07, 2014, 02:03:19 PM »
Right.  Yeah, I did do that.  I've slacked and tightened that damn cable more times than I care.  I really thought cleaning it had worked, before I fired it up.  It moved well with the clutch lever pulled and I couldn't push it with it released.  That felt better than before where it would feel like it was dragging with the clutch pulled.  But... I guess these dang plates are just warped.  At least now, it seems, I know.  I think I was quoted a few hundo for all the plates and some new springs from NField.  I'm pretty sure this AVL has cost me more in parts than it did to buy the whole machine at this point.  It's frustrating.
2007 AVL
2006 DRZ400SM

Blltrdr

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Re: Cannot adjust clutch on AVL
« Reply #67 on: May 07, 2014, 05:45:40 PM »
Right.  Yeah, I did do that.  I've slacked and tightened that damn cable more times than I care.  I really thought cleaning it had worked, before I fired it up.  It moved well with the clutch lever pulled and I couldn't push it with it released.  That felt better than before where it would feel like it was dragging with the clutch pulled.  But... I guess these dang plates are just warped.  At least now, it seems, I know.  I think I was quoted a few hundo for all the plates and some new springs from NField.  I'm pretty sure this AVL has cost me more in parts than it did to buy the whole machine at this point.  It's frustrating.

It can be frustrating. If you feel you have put more money in the bike than the amount of enjoyment you have received from owning it then it might not be the right bike for you. But I would bet that you deal with this clutch issue and solve it that this will be a fun bike for you. Funny how things change once you sort things out. Any way good luck. Clutch is pretty simple. Hitchcock's sells a clutch service kit that has the friction and steel plates plus 3 std springs and 3 HD springs for $115. I'm sure Nfield Gear can get that same kit for you. Sounds like it might have got pretty hot. Like Ace suggests, replacing the steel ball that the clutch rod pushes against with a ceramic one will also help minimize friction. I can't remember the size but you should be able to find it doing a search. You could probably source one locally. Also replacing the clutch pad with one that has the bearing is an improvement. Myself I replaced my stock 5 spd clutch pack (crap) with an upgraded 4 spd pack using Hitchcock's Surflex friction plates and the stock metal plates from the 5 spd pack. Works perfect
« Last Edit: May 07, 2014, 06:02:07 PM by Blltrdr »
2003 Classic 500 5 spd
1992 Kawasaki ZG 1200 Voyager XII
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boggy

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Re: Cannot adjust clutch on AVL
« Reply #68 on: May 09, 2014, 11:58:59 PM »
It can be frustrating. If you feel you have put more money in the bike than the amount of enjoyment you have received from owning it then it might not be the right bike for you. But I would bet that you deal with this clutch issue and solve it that this will be a fun bike for you. Funny how things change once you sort things out.

You are right. When it's running - it's incredible.  I got a second bike so I didn't have to worry about not having a working moto which was a major life upgrade.  I'll probably never sell the AVL.  I have dreams of a glorious machine - it may just take some time. 

Thank Blltrdr,
Boggy 
2007 AVL
2006 DRZ400SM

boggy

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Re: Cannot adjust clutch on AVL
« Reply #69 on: August 16, 2014, 05:41:34 PM »
Have some new Barnett friction plates and stock steel plates.  Just want to sanity check...

The only directional plates are the 2 dished steel plates on either side and the friction plates and the steel plates are not directional, correct?

Thanks.
2007 AVL
2006 DRZ400SM

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Re: Cannot adjust clutch on AVL
« Reply #70 on: August 16, 2014, 06:01:29 PM »
If you have 3 steel plates they should be assembled like this:    )|(

4 plates like this:   )||(

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boggy

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Re: Cannot adjust clutch on AVL
« Reply #71 on: August 16, 2014, 06:22:01 PM »
Great, thanks.  Like those technical drawings  :)
2007 AVL
2006 DRZ400SM

boggy

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Re: Cannot adjust clutch on AVL
« Reply #72 on: August 16, 2014, 07:50:44 PM »
I'm out of room on the inner part of my clutch basket before all the plates have been replaced.  The new Barnett friction plates are a good deal thicker than the old stock ones.

The first picture is the old plates: 5 steel (2 dished/3 flat) + 5 friction.  The arrow is pointing to the basket's inner edge.

The second picture is the new plates. In that photo there are ONLY 4 steel (1 dished/3 flat) + 3 friction plates.  I haven't put any more in because as you can see I'm out of room on the inner edge.

The third picture is the full stacks of each: 5 steel + 5 friction.

Are their different sized steel and/or friction plates for 4 and 5 speeds or do you just use a different # of total plates?  I did specify that I had a 5 speed.  Do I simply use 1 less friction plates and 1 less flat steel plate?  When I remove those, the stacks become even.
« Last Edit: August 16, 2014, 08:26:12 PM by boggy »
2007 AVL
2006 DRZ400SM

boggy

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Re: Cannot adjust clutch on AVL
« Reply #73 on: August 16, 2014, 10:34:57 PM »
Going with 4 friction + 4 steel. 

Went back in this thread and saw your note on this Blltrdr.
http://www.enfieldmotorcycles.com/forum/index.php/topic,17939.msg202506.html#msg202506

Thanks.
« Last Edit: August 16, 2014, 11:50:06 PM by boggy »
2007 AVL
2006 DRZ400SM

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Re: Cannot adjust clutch on AVL
« Reply #74 on: August 17, 2014, 04:05:44 AM »
Boggy - You are going to need BOTH dished steel plates in the assembly for it to work right.  If the Barnett plates are too thick, then you will want to remove 1 FLAT steel plate and 1 friction plate.  If you don't have the dished plates on the outsides of the assembly the clutch is not going to function properly.

Scottie J
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