Topic: Clutch with no resistance....

[sh1bby69]

Alright so I replaced the oil pressure switch and noticed that there was a lot of gunk on the back side of the cover. So I decided to disconnect the cable and pressure wash the inside of that cover. All I can say it was very sticky and caked on hard. I did the best i can to remove most of it and free up the mechanism that held the clutch cable which I thin could have caused it to stick sometimes. Now after I reinstalled everything there is no resistance in the clutch at all. With the bike on it's center stand I can shift through the gears without using the clutch. When squeezing the clutch lever it doesn't seem like it's engaging the clutch at all.

What did I do and how can I fix this?

[the technological J]

my guess is that you reassembled the clutch cable to taught(?) over tight ttry to loosen the adjustment up some

[camelman]

Isn't there a ball bearing in there?  If you pressure washed it, then I imagine you knocked it out of its hole.  It is held in by grease, so it wouldn't be hard if you are removing the grease.

Camelman

[sh1bby69]

The lever I can play around with no problem. I have read about the ball bearing that is pressed against the clutch rod and I seem to have lost that.

Also what I noticed is then I was removing the cover is that I removed the Clutch adjuster locking bold not knowing that it was attached to something inside. I thought it was one that was holding the cover. So I reinstalled it. So you think if I can find a replacement ball bearing and played with the clutch adjuster I can get the clutch back to normal??

[the technological J]

 we are talking about a 500 right? i think that if y ou lost the ball bearing you wouldnt be able to disengage your clutch it would be engaging at all ... someone correct me if im wrong.... i think that if you adjust your clutch(by the adjuster) start her up and (find a friend) keep testing the clutch as you let the adjusting nut out

[the technological J]

is your clutch staying engaged or not engaging?

[sh1bby69]

Basically it doesn't engage. I squeeze my clutch lever and it does nothing but pull on the spring on the cover...but I am still able to shift through all the gears when up on center stand without using the clutch.

[Frostyboy]

From what you're saying about being able to shift through the gears on the centre stand, I'm assuming the back wheel is spinning. If you apply the rear brake to stop the wheel I reckon it will stall the engine.
If that's the case, the clutch is not disengaging. Find the ball, put it back & go through the adjustment procedure and all should be good.

[sh1bby69]

From what you're saying about being able to shift through the gears on the centre stand, I'm assuming the back wheel is spinning. If you apply the rear brake to stop the wheel I reckon it will stall the engine.
If that's the case, the clutch is not disengaging. Find the ball, put it back & go through the adjustment procedure and all should be good.

alright thanks! if I can't find the ball from what I can understand from the parts manual it looks like a 5/16 size ball bearing correct?

[Frostyboy]

It's all a bit different to my 550, however I'd imagine it would be a metric size. 8mm is more likely the case if your 5/16" close to the mark.
I don't know how much tolerance is allowed, but I would imagine the parts book for your model might state the size.
Cheers.

[KingCustomCycles.com]

insert new ball, pack hole with grease so the little monkey will stay in place, reinstall cover and adjust.  The clutch cable pulls a cam riding on a couple of balls also that rotate on a plate.  If your plate is moving in and out with pulling of the cable, that part is assembled correctly and will just need adjusting.

[sh1bby69]

Thanks everyone! i'm going to try and search for that ball in all the gunk I cleaned out of it. Hopefully I'll find it if not I'll have to check Home Depo or even have to order it online.

[MoMo]

You can get ball bearings at most any auto supply and save yourself some waiting time, Larry

[sh1bby69]

Is there a part number for the clutch rod seal? I see in some people picture there is a seal around it. Mine doesn't have it