Blue Beast
Parking Attendant
Posts: 11
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posted May 16, 2007 08:00 AM
Clutch Installation Problem
OK guys I'm new to this but here goes..........I've got an '00 12R and I purchased a set of muzzy clutches for it yesterday. I already had the Muzzy basket and everything. Well, we got all the plates in so we put on the cover, put the rod in, and attached the cable. But for some reason i'm not gettin much tension on the clutch. I have to adjust the cable all the way out above the clutch cover to the end to get even a little tension on it and even then it's not much b/c when it shift in to 1st with the clutch all the way in, the bike takes off. What could be causing this? My next question is, is there supposed to be any "play" in the little rod that comes between the clutch plates and basket that the clutch rod actually latches onto? PLEASE HELP ME!!!!! I have only about a few days to get it back together before I leave for the beach! I'm open to all suggestions.....PM me if you need to!!!!!!!!!
  
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dougmeyer
Needs a job
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Posts: 2713
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posted May 16, 2007 08:50 AM
Pay very close attention to the instructions regarding the placement of the plates that came with your clutch kit. Use only those plates.
Make sure that you have the washer and bearing stack for the puller shaft correct.
Make sure that you have the puller actuator shaft out of the cover when you bolt the cover on, insert it and with the releif in the shaft in a position allowing you to slide the shaft into place over the puller pin and, by feel, make sure the notch in the shaft properly engages the pin. Do not let the shaft drop below this position when installing the cable. (use a rubber band to hold tension on the lever to hold it against the pin. You will need to readjust the cable some, but not as much as you are finding.
Do you have a stock shop manual? Everything except the plates is done the same as in the manual. If you don't have a manual. GET ONE, and start completely over.
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Blue Beast
Parking Attendant
Posts: 11
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posted May 16, 2007 09:06 AM
When I pulled the old plates out I stacked them exactly as they came out and zip tied them to be sure of the placement. I do believe I was getting the actuator on correctly because it felt like it was on and when I tried to gently pull up on it, it wouldn't come up. I don't have a shop manual but I think my buddy has one. I have a buddy of mine looking at it now, if he doesn't have it fixed by time I get off and head to the shop then I'll try everything you suggested. Thanks doug!
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madmike
Moderator
FEAR THE BLACK FLAG!!!!!!!!
Posts: 6579
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posted May 16, 2007 10:04 AM
are you using the old steels? or the complete Muzzy fiber and steel set?
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Blue Beast
Parking Attendant
Posts: 11
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posted May 16, 2007 10:05 AM
I got the complete set. 11 fibers and 10 steels.
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Stuart Racing
Zone Head
N.H.R.A . Dragracing.
Posts: 999
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posted May 16, 2007 10:43 AM
Check the measurement of the steels...Just took mine apart and the person that had it before me must not have known that they were different because all the steels were 2.0's and the fibere's WERN'TMuzzy's....Standard steel's are 1.6's....I bet your steels are standard's 1.6's....
Let us know what ya find...
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Life in the Fast Lane..........
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Blue Beast
Parking Attendant
Posts: 11
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posted May 16, 2007 10:50 AM
I compared the two stack heights yesterday too and they both measured the same. I'll check again though. Thanks for the suggestion Stuart!
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entropy
Moderator
Posts: 8671
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posted May 16, 2007 11:20 AM
 Edited By: entropy on 16 May 2007 20:33
do you have little ot no play in the clutch puller rod?? If not the slack height is too low; like others pointed out you prob don't have 10 x 2.0 steels.
BUT since you aren't getting enough pull to disengage the clutch, it seems that yr clutch stack is too high.. (does the puller have too much play?)
OR
maybe you misplaced that lil washer which goes between the roller bearing on the puller and the pressure plate. That'll give you a very loose puller, acts just like a real thick stack, and makes the clutch real hard to disengage (no adj left).
Just a thought
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dougmeyer
Needs a job
moderated
Posts: 2713
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posted May 16, 2007 11:20 AM
The Muzzy hub does not require the Muzzy supplied clutch pack, you can use a stock set up and stock springs if you wish but you just cannot mix the two setups. Use all Muz or all stock. The greates benefit is in the increased oiling from the Muzzy hub and puller.
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Blue Beast
Parking Attendant
Posts: 11
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posted May 16, 2007 11:26 AM
I'll check the washer.
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Blue Beast
Parking Attendant
Posts: 11
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posted May 17, 2007 03:43 AM
The rod does have play in it but I'm not sure what is too much or what is too little. I'll call the shop today and double check the size of the steel's. I pulled everything out again last nite to check for the washer and it was there, along with the roller bearing.
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madmike
Moderator
FEAR THE BLACK FLAG!!!!!!!!
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posted May 17, 2007 04:59 AM
quote:
Check the measurement of the steels...Just took mine apart and the person that had it before me must not have known that they were different because all the steels were 2.0's and the fibere's WERN'TMuzzy's....Standard steel's are 1.6's....I bet your steels are standard's 1.6's....
Let us know what ya find...
what were the Fibers?
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Stuart Racing
Zone Head
N.H.R.A . Dragracing.
Posts: 999
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posted May 17, 2007 07:01 AM
He said EBC'S....All the steel's are 2.0's.....The fiber's were WORN OUT....Bad setup...Shoulda checked it out before....
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Life in the Fast Lane..........
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Stuart Racing
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N.H.R.A . Dragracing.
Posts: 999
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posted May 17, 2007 01:13 PM
Blue Beast,I put the one different looking plate in first and then work your way out from there....My stack height came to 2.2375,cable adj. just right....Like Doug says,follow directions the way it says...If you put the different looking plate in last , you already know what happens.....Check it out....
Paul.........
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Life in the Fast Lane..........
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dougmeyer
Needs a job
moderated
Posts: 2713
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posted May 18, 2007 09:55 AM
That's why they're called DIRECTIONS. 
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blue beast
Parking Attendant
Posts: 11
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posted May 18, 2007 10:02 AM
Found out what it was....the rod bearings weren't in the in the clutch cover. When I ordered the cover from KAW they didn't tell me the bearings weren't going to be in it. They just told me that I needed to get the top oil seal. Needless to say, I took the old bearings out, popped em in the new cover and we got tension! Off to the beach fellas!!!!! Thanks for all the input. (we seem to always overlook the small, simple things)
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Stuart Racing
Zone Head
N.H.R.A . Dragracing.
Posts: 999
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posted May 18, 2007 06:27 PM
Got mine together WITH, NOX's lockup & setup....Took it for a ride and was verry nice..NOX did his homework...Gonna try it at the track tommorrow...Thanks a bunch for the help NOX,much apprciated ok..
Paul......
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Life in the Fast Lane..........
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