Clutch not disengaging.
 

Here's the deal. Just replaced my clutch. I uninstalled everything and then re-installed the new plates and springs.

I got the EBC Heavy Duty clutch and the Vesrah Heavy Duty Springs.

Only problem is... there is almost no pressure on the clutch lever when I squeeze it. The little pushpiece in the center of the clutch plate assembly does not seem to contact the pressure plate to push it to disengage. What could be causing this.

BTW, I left one plate out, just to see, and the clutch lever pressure returned and would disengage - but the clutch would not drive the rear wheel. So... leaving a plate out is not an option.


Any help would be gratly appreciated. Thank you in advance.

Did you set the free play properly at the lever end and the engine end?

Yes. I adjusted the thing as far as it could go... to my knowledge. Maybe a shorter clutch cable??? I don't know. Oh yeah, maybe I should have mentioned I just did a GSXR 1000 front end swap. But I rode it (testing) right after I did that then put it back up on stands to swap the clutch. So... I don't think it's relevant because the old one worked (as well as it was before) after the swap.

Has the cable snapped?

Me think its the worm drive that stuffed.

I was coming to that :P

adjusters on the cable are cable adjusters, not clutch adjusters

is locknut & screw clutch adjuster under the clutch cover adjusted correctly, sounds like it's backed out too far and does not disengage the clutch

The cable is fine. The worm drive? Explain more please.

Its the little thing that goes into the bottle.. naaa only joaking


Its part of the mech thats pushes the clutch rod to disengage the clutch, if the little ball bearings inside have gone then it will just rotate without pushing the rod as the ball bearings run on ramps (worm bit) and without them it does not work. It is a good explanation to why you feal the clutch is very light because you are not actualy pushing the clutch in.

On reading you original post again, did you make sure you installed the plates correctly, there is one plate that is smaller and if its be installed incorrectly then mabey the clutch pack is too big and thats why you cant disengage the clutch.

Also, could it affect it if I did not install the new plates in the right order? I don't know how... just wondering.