Not VMX sorry, but help needed anyway - Suzuki JR50

[YZ250H]

Just replaced all the clutch plates in my son's JR 50.  All went very well until I went to put the clutch cover on.
It won't seem to engage/disengage the clutch  .

Anyone any experience - it is 2005 model, but it appears the set up has been the same since 1985 (I almost made vintage    )

[oldfart]

Are the plates  the right thickness as per shop manual

[YZ250H]

Yeah, that part of it is OK Stew.  it's the interaction between the selector and the clutch actuator.  I will post some pics to show you what I'm on about.  Stay tuned 

[mainline]

Did you put the shift lever on the correct splines? It might be hitting the cases or frame?

[YZ250H]

Hardy Har Friggin Ha 

[lukeb1961]

when you put the clutch back in, there is an adjuster nut/bolt affair in the centre. This changes the take-up.
if it was adjusted for worn-out plates, you will need to alter it. Did you check that?

Luke

[YZ250H]

Yes Luke,

I have had it going  with these plates.  When I replaced the plates I noticed the pins on the plate at the back were very worn.  When I put the new plates in the bike still didn't want to pull very hard, so I ordered the new plate with the pins and fitted that this morning.  Sorry should have told the whole story at the start.

Took some photos, so here goes.
The actuator connected to the gear lever is the slide type arrangement.  It moves up when you select drive (shown in the up position).  The spring seems to want to sit in the middle, but I moved it to the side to see if that was the problem.


View from the back side.  I think that actuator works against the little bearing on the right hand side.  This converts to movement of the motor side plate that engages / disengages the clutch (I think).



View from the outside.


The only thing I can think of is that I have tried to screw the side cover on when the bearing was in the wrong position and bent the arm it runs on.

What do you guys reckon ?  I have had it back together before and had no dramas.  That's why I can't work it out 
 
Just looking at the marks on the kick start housing maybe my bent arm theory is right

[oldfart]

Yes definately something not lining up if you have scuff marks ..... in pic # 1

[lukeb1961]

so when you change gears from neutral, do you feel a very clear thunk?
oh, the clutch is totally not engaging, right?

The release arm looks ok. But the link arm appears to be pushed out. (the bearing near the kick-starter shaft). Hard to be sure. In that photo close-up of the cam-stopper (yes, the spring should be in the centre) you can see the scuffing on the kick-starter spring stopper. Looks like it all went wrong about there? My bet is it got jammed and was never going to move. Your photo shows it in 2nd gear, so make sure it is in neutral and the kick-starter bolt thing removed too. It should slide on without any over-enthusiasm being required.

cheers!
Luke

[YZ250H]

Thanks Luke.  I think everything is pointing to a bent arm that the bearing runs on.  I will pick up another and see what happens.

Thanks for all your help guys.

[lukeb1961]

Just pop it out, straighten it a bit and put it all back. It isn't under much load - except when you shove it in wrong    My bet is all will be well with 5 minutes of persuasion.

[YZ250H]

No worries.  I'll give it a crack.  Have to think outside the square though as I don't have a vice 

[YZ250H]

Ok bought the new part - $31 

It still didn't engage when the motor wasn't running, so I put the damn thing back together anyway just to see what would happen.

Turns out it only engages / disengages when the engine is running 

Just a note for future reference   

The kids have had a ball on it, so it has all been worth it    Thanks guys for your help - much appreciated.