Clutch trouble

[newman]

 
Put in a new clutch last night but having problems!
Without using the clutch lever the gears are engaging and I can cruise through the gears freely.  Took the sidecover off to have a squiz and I clicked all the way to the top gear and now the clutch pedal doesnt move.
I tightened the lock nut to 90-ish newtonmetres (too tight??).  I also have brand new clutch springs...
The bike is a '95 XR200, Any ideas??

[David Lahey]

Please have another go at describing the problem

[090]

Clutch pedal? I assume you mean gear lever?
Make sure the outer clutch hub cover is lined up with the internal ridges of the clutch hub inner, if you know what I mean. That is the cover you put on before putting the clutch springs in.

[newman]

Have replaced clutch friction plates, clutch springs and clutch cable.  Put everything back together and tested clutch lever, which was loose/ had no tension.  I was able to change through all the gears easily without even pulling on the clutch lever.  I pulled off the sidecover to have a look, and now it is stuck in top gear...

[Hoony]

did you lay the bike on its left hand side to do this ?

if so the gear shaft may be misaligned. drain oil and have another go at it with bike upright. oil

[newman]

Clutch pedal? I assume you mean gear lever?
Make sure the outer clutch hub cover is lined up with the internal ridges of the clutch hub inner, if you know what I mean. That is the cover you put on before putting the clutch springs in.

Yep sorry, meant gear lever.. just had a brain fart whilst typing
Should the clutch hub cover sit flush with the clutch casing? The clutch hub cover is sitting 3-4mm higher than the sides of the clutch casing at the moment...

[newman]

did you lay the bike on its left hand side to do this ?

if so the gear shaft may be misaligned. drain oil and have another go at it with bike upright. oil

Yes, the bike was lying down when I did it.

[David Lahey]

It is probably in a gear and can't shift because you have tricked the shift mechanism by shifting without either of the gearbox shafts being in motion. You may be able to get it working again by rocking the gearbox via the sprocket or the crankshaft.
Another possibility for the clutch is that something has fallen out of the clutch release mechanism (like a thrust ball), or you have the wrong cable. You haven't said if the clutch is driving or free. Its normal to be able to change gears without pulling on the clutch lever.

[newman]

What do you mean by driving ? If i lift the back whell and turn it over by hand the rear wheel does not turn with it. Could that be because its in top gear ?

[David Lahey]

If the crankshaft/piston moves when you turn the rear wheel, it is in a gear and the clutch is driving
If you move the crankshaft and the rear wheel doesn't move, then it is either in a neutral or the clutch is not driving

[Hoony]

read your email i cannot post my long reply for some reason, sent it by email

[newman]

yep, the clutch is driving.

[090]

Yep sorry, meant gear lever.. just had a brain fart whilst typing
Should the clutch hub cover sit flush with the clutch casing? The clutch hub cover is sitting 3-4mm higher than the sides of the clutch casing at the moment...

The cover should be hard up against the clutch plates. It needs to seat properly. It can be misaligned.

[newman]

should there be movement in the friction plates when everything is back together , but the side cover is still off ?

[Davey Crocket]

Are you Newman off Crammer?