Topic: Stuck/locked kick starter after clutch install? Need help!

[Cleric40]

Hello experts,

This past winter I rebuilt my cb500 engine. I am getting around to installing new clutch plates tonight and after install I went to turn motor over with kick starter and it was locked up..?  No movement! Before installing the plates the kick moved freely. If I pull in clutch the kick can move freely but does not turn motor over. Doing all this with plugs out.



I know motor is free as I can turn it over by both a wrench on crank nut, as well as with rear wheel if up on center stand and in gear .

Am I missing something or some newb mistake here?

Any help would be greatly appreciated to get this baby back on the road!

Thanks in advance


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[Restoration Fan]

If you have the front sprocket on the engine, try turning that a bit and then changing the gears or engaging the kick starter.  If not, try turning the rod that the sprocket sits on.  The transmissions on these bikes sometimes need to be rocked forward or backward to change gears (although I haven't heard of it affecting the kickstarter, I could see where it would potentially be an issue.)

[Cleric40]

Thanks resto Fan. I have tried this as well with no luck...

I'm stumped . Anyone else have any suggestions?


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[Jore]

Most likely it's the clutch plates, I thought that my motor was stuck from sitting for over a year, I tried moving the kick starter and it was completely stuck, not even standing on it would move it. But when you pulled the clutch it was free, same deal with the motor. I asked in the forum and someone told me that over time the clutch plates dry out and tend to stick, giving the aforementioned effect.

[Cleric40]

Hmm. I soaked the plates before installing. So I would hope that would reduce any dry effects...

Could they be too thick causing issue? They are Barnett plates

Update:  I reinstalled the old worn plates and had the same issue of no movement with kickstarter


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[Cleric40]

All,

I am needing some more help or direction here. Anything you may check or look into further would greatly be appreciated

I took apart the whole clutch again to verify correct plate orientation and everything looks good.

Looking at the manual I may be missing a part but don't think it's causing the issue. In pic below, I do not have #8 or 12 but don't think I ever had it even with old clutch (that didn't have issue). Also my steels aren't different as they appear in diagram.

Lastly I tried rolling the bike down street a bit to see if this could get things moving since sometimes they need a little rocking and even with the plugs out of motor the rear wheel was dragging/skidding. I could only get it to turn motor over if I really leaned into it and then it would turn ok. Does this seem normal?

Any suggestions? I am so close to getting this baby running and this is stumping me!


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[Restoration Fan]

My 78 has slightly different parts but I have to believe that spacer and clutch plate stopper ring are pretty significant pieces.

Have you tried removing the clutch plates altogether, putting it in neutral and see if it will roll that way?  If it does, then that tells you that the problem is indeed your clutch and the way it's installed.

Ron

[Cleric40]

I will try your suggestion. But what is confusing me is that it worked fine before with the old clutch and it didn't have those parts...

Anyone else have any tips? Are spacer and clutch plate stopper ring absolutely critical?


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[Cleric40]

I tried removing plates and bike did indeed roll. But what I am wondering is if something is jammed up with the primary gear.

Even if plates were too tight, it should still be able to try to kick over right?

Can anyone confirm different steels?

Also the spacer and stopper ring significance?

I am working on tracking down those parts, but in the meantime just wondering

Update:added video for further clarification


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[Cleric40]

Bump. Anyone?


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[Restoration Fan]

With the plates removed, are you able to change gears then? 

I'm not a believer in coincidences and the problem started when you changed the clutch, so it's fairly obvious that something in the clutch change caused it to lock up.  And since the back of the clutch basket has the gear that connects to the transmission, it's not hard to think that improper installation of that clutch basket could be a problem.

One other point...these transmissions sometimes want you to rock the bike back and forth a bit to allow the gears to change.  So try that to make sure the problem is really an issue.