Worn clutch?

[RyanTZR125]

This morning I took off my clutch cable, to fit some new cable adjusters to the lever (I had some chopped BMX ones on it) I removed the lever and disconnected from the the lever housing, screwed on the new adjusters and fitted it all back together. The lever was very tight now, so added a little adjustment at the the engine end to slacken off a bit.

So now the clutch doesn't engage at all, I can knock into gear but when the levers released, the bike wont move. I've tried various adjustments to the cable at both ends, but no change.

I wonder if I've put too much pressure on the plates while refitting the cable. As I left the cable attached at the release mechanism, would the extra tension crush the friction plates,
Any ideas? I guess this weekend I'll be rebuilding a clutch then

I haven't taken it apart yet, but may as well do a complete over haul while its apart.
Order so far, missed anything? I've never done a clutch so any info and advise will be a great help
Honda H 100 A (80-83) Clutch Cable
Honda H 100 A (80-83) Clutch Friction Plate Set (3)
Honda H 100 A (80-83) Clutch Spring Bolt & Washer Set
Honda H 100 A (80-83) Clutch Spring Set (3)
Honda H 100 A (80-83) Clutch Steel Plate
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1980 Honda H100A, Cafe racer. (SOLD)
1998 Yamaha TZR 125 4HX.
1999 Yamaha R6 YZF

[mudcow007]

i would imagine its a very similar setup as the CG

i replaced my clutch last week, an have noticed weird goings on with the cable too

on the case its on the largest adjustment, the same at the lever?

i also found the bike was slipping really bad not long after i had refit everything, turned out the bolts holding the springs in had loosened off

[stinkwheel]

If I read this right it went (chronologically):

1) Clutch working.
2) Mess with cable.
3) Clutch not working.

As such, you haven't got it reassembled properly because nothing you could have done to the cable would damage the clutch itself.

I'd be looking at the clutch release lever on the RHS crankcase cover as my first port of call. I wonder if you've managed to flip it round/get it jammed or similar.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[RyanTZR125]

The release mechanism wasn't touched, i took the lever off the handle bar, to give me enough slack to remove the cable, leaving the mechanism end as it was. Screwed on new adjuster put the lever back together. Pull the lever the mechanism moves freely up and down, but no release on the clutch.
____________________
1980 Honda H100A, Cafe racer. (SOLD)
1998 Yamaha TZR 125 4HX.
1999 Yamaha R6 YZF

[mudcow007]

is the adjuster the same size? as in does the cable go further into the new adjuster?

[stinkwheel]

Just dive right in there and replace the entire clutch without checking the release mechanism.

No skin off my nose.

Remember, if the clutch isn't gripping, the plates are being held apart by something.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[RyanTZR125]

[lihp]

Put in gear, and remove cable. see if you have drive
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covent.gardens: lihp is my most favourite member ever

[Ariel Badger]

[jeddy11]

[RyanTZR125]

[lihp]

Do what I said above and it will prove the diagnosis
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covent.gardens: lihp is my most favourite member ever

[andym]

Not that I know anything, but doesn't doing anything to the clutch cable release the tension on the clutch arm.

You need to get the tension back on the arm before adjusting at the bar... unless you've got bloody good adjusters

[RyanTZR125]

Panic over, I removed the cable and rocked bike back and forth in gear, and the gears engaged. Was just a case of re fitting the cable and finding the correct tension on the adjusters
____________________
1980 Honda H100A, Cafe racer. (SOLD)
1998 Yamaha TZR 125 4HX.
1999 Yamaha R6 YZF