Topic: installing clutch actuator ??

[mono]

for some reason the forum search isn't working, so i'm running a new thread.

I'm ready to put my clutch cover back on and need to install the lever, but for some reason it's not holding in place.  i'm thinking that it's like setting a rat trap and that the center pin on the clutch is what keeps everything lined up, but any tips anyone can offer would be helpful.  i just did a fair bit of spitting and cussing.

going to go try my theory - any input in the meantime would be good in case this doesn't work for me.

[mono]

think i got it - used something to hold the actuator arm up a bit, which allowed the "rat trap" to stay in place...

[mono]

nope!  after bolting it on, as soon as i released the clutch lever the *(^(*&^*&%$*%)()( went *clink* and fell off that rocker and the clutch lever is stuck. 

any help would be fantastic.  do i just need to keep something wedged under the clutch lever until i reinstall the clutch cable?  i don't see why i'd have to since after i removed the clutch cable i could lift the clutch lever and it would lift/fall with tension.  maybe the bike was in gear or something when i parked it?  i don't think so, but...

ideas please.  can't drive it if i can't use the clutch.  hooray!

[dave500]

you might have installed that little cam lifter backwards?

[crazypj]

Take a picture of the complete clutch cover and clutch
 I haven't done one for a while but used to do 550 transmissions now and again when working for dealer (2nd gear) and don't remember having a problem re-fitting clutch or cover.
I have seen clutch assembled wrong multiple times.
You do have the push-rod in clutch center?

[mono]

yeah the push-rod is in there.  after failing to install it i noticed that there are position marks on the outside.  I'll just have to shim it up to hold it in place until i get the clutch cable hooked up.   

[dave500]

it shouldnt need to shimmed up to install it,those dots are for the final adjustment,i find they arent real accurate though and adjust by feel,your supposed to adjust the primary setting,thats the screw and lock nut on the case untill those dots line up,then do the cable,if it slips adjusting the screw in slightly gives more bite.

[crazypj]

Leave lock-nut loose at bottom of cover, UNSCREW screw until the 'notch on arm lines up with dot on cover.
If you screw in normal direction it moves the pivot point away from clutch and gives too much travel.
All the plates are in spec?

[mono]

i'm guessing that the plates are OK - it's only got 10K on it, and i haven't taken the actual clutch apart.  the only thing i did was remove the cover to polish it up.

i'll fiddle with it tomorrow and ppost some more pics if i'm still stumped.

thanks for the help so far, guys! 

[vincentlefre]

I'm kind of having this same problem at the moment. Is the photo of the assembly in the first post showing it correctly assembled or is there any truth to the comment about the cam being in upside down?

[LesterPiglet]

EDIT. This diagram shows it assembled like your picture.

[mono]

sorry guys - i figured this out a while ago.

MY PROBLEM WAS:  i had the adjuster screw backed out too far.  it's hard to explain, but it's simple geometry i guess.

since the screw was "too tall" inside, it raised the lever up, causing it to "shorten" how far it reaches.

moral of the story:  screw in that bolt a lot and then back it out as needed after the clutch cover is mounted.   doing it this way let me adjust it down until it could shift again.

after realizing what i'd done, i literally slapped myself on the forehead and said "DOH!"

thanks for all the help though, fellas!