Sticking clutch linkage

[Rossco]

Well after replacing the clutch plates on my 83 Honda VT500c, and getting it back together, I can't now seem to get the clutch lever to work properly.

The clutch lever will pull back, with resistance to the handlebar grip, but will not retract back to it's natural position. The only way, I can get it back into position is by manually actuating the clutch arm on the side case.

Oh, and it's a cable clutch. Any ideas (aside from smartass comments) would be greatly appreciated. Thanks in advance!

[Awesome]

Plates aren't in right, you forgot the springs, actuator isn't seated properly.

[Eric Baker]

My first guess would be the linkage on the clutch cover is not lined up properly. Or you forgot the return spring on that linkage.

[Rossco]

My first guess would be the linkage on the clutch cover is not lined up properly. Or you forgot the return spring on that linkage.

By return springs, are you talking about those four springs that go behind the bolts on the pressure plate?

[TheIglu]

By return springs, are you talking about those four springs that go behind the bolts on the pressure plate?

Yup.

[Rossco]

Ok took another look at it this weekend. Everything was in there fine. I noticed that the clutch arm was actuating fine when it was disconnected, however when it was connected it didn't spring back.

So my guess is that the cable got so stretched that it was unable to provide enough tension to cope with a newly installed clutch. I've ordered a new cable and should have that on in a few days. I'll keep you guys posted.

[Rossco]

Yeah, tried a cable and that's not working. Clutch still won't engage. I've given up on trying to do this myself. Anyone know of any good shops that can do a clutch replacement?

Anyone know how much an install for new friction plates and springs costs? I know this probably won't be cheap, so I'd rather have it done at a good place then take it to a stealership and have someone half-ass it and charge me a fortune.

Thanks in advance!

[Rossco]

Well, my bike is currently at a shop. It's been there for the last 3 weeks or so. When I went down there last week, they finally got started on it. they had it all torn apart and had the clutch basket removed.

They were comparing the clutch assembly to the diagram in the repair manual and trying to figure out if something went in wrong. They seemed pretty perplexed by it. They really didn't see anything out of the ordinary.

[butcher bergs]

While I am not experienced with the set up of your particular machine, what are the chances that the friction plates have a certain orientation within the basket?

I've seen specific instructions in the past on some bikes that state the friction plates must be installed with certain tabs pointing in certain directions.

For example: "...the blue tab faces 2 o'clock and the yellow tab faces 11 o'clock..."

[Rossco]

While I am not experienced with the set up of your particular machine, what are the chances that the friction plates have a certain orientation within the basket?

I've seen specific instructions in the past on some bikes that state the friction plates must be installed with certain tabs pointing in certain directions.

For example: "...the blue tab faces 2 o'clock and the yellow tab faces 11 o'clock..."

Hmmm....
I didn't see any type of color coordination, or punches or any markings on any of the tabs on either the original clutch plates, or the EBC ones I installed.

[Danz19899]

ohhh i get what bergs is getting at. Also have no exact knowledge of your bike but the plats definitely could have a tab sticking of them that might not be lined up and is contacting something so the clutch plates can compress together. So look around the outer edge of all the plates see if the have a tab coming off any of them

Only seen those type of friction plates on a Chrysler auto tranny but that would explain all of your issues

[TheIglu]

I think you need to find a new shop, or someone that is willing to give it a look for a 6-pack. Hell, if you got it to my house one night, I'd be willing to take a look at it.

Clutches are not that hard. Then you can have a bike to ride while looking for a GOOD deal.

[Sheppo]

Hey I recommended the shop and the person is very knowledgeable. If he is perplexed something outside of the norm is acting up. I wouldn't bring a newer FI bike to him, he is old school and that's his clientele, BUT he knows what he's doing.

[TheIglu]

Not saying anything about the shops knowledge, but 3 weeks is a long time before they even take a look.

[Rossco]

Not saying anything about the shops knowledge, but 3 weeks is a long time before they even take a look.

Oh they had it apart last time I was there. In fact, It think I might swing by there real quick to see whats up.....

[Sheppo]

Not saying anything about the shops knowledge, but 3 weeks is a long time before they even take a look.

They had looked at it with in the first week.

[Rossco]

I just got back from the shop. The owner there said he believes the culprit is the clutch springs. He said he ordered some and if they arrive tomorrow, I should have the bike by Saturday.

I kinda doubt that will be the case, seeing as my luck with this whole clutch fiasco has been pretty shitty, but I'll keep my fingers crossed.

[Rossco]

Aaaaaaannd I was right. Still no bike.

The bike was supposed to be done on Saturday. Get call on Saturday from shop. Mechanic says he "got distracted" and wasn't able to complete the bike on time. Check in today to see whats up only to find that they have BROKEN THE CASE COVER putting the bike back together.

The mechanic there says he can rig something up to fix it. I am quite skeptical at this point.

[TheIglu]

Yup.

Next time, just find a truck and a large pizza and come on out.

[Rossco]

Well, the shadow is working again. The guy rigged up a temporary cable guide, but he did charge me alot less, probably to compensate for the broken part. So I'm happy

[TheIglu]

If you want, next time something like this happens just bring the bike to me. I'll break it for less than he charges.