DrGonzo said:
nah i havent touched anything with my clutch or my levers.
It doesnt feel like the clutch is engaging when im at rest though, i dont feel any engine pull.
BTW my bike has about 5400 miles on it, as far as i know, the clutch has never been replaced
If you have not touched the levers, you should check your pushrod and the throw-out bearing on the pressure plate. You might have a damaged pushrod and/or seized throw-out bearing. The pushrod goes from the slave cylinder through the case to the pressure-plate on the opposite side. The throw-out bearing resides in the pressure-plate.
You can remove the pushrod by first removing the clutch cover and then loosen the six bolts that hold the clutch springs. Remove the pressure-plate. There is a pin at the end of the pushrod that holds the pushrod in the throw-out bearing of the pressure-plate. If that is stuck, when you remove the pressure-plate, the pushrod comes off with the pressure-plate. If the pin is not stuck after you remove the pressure-plate, you can then pull the pushrod out.
If the pushrod is damaged or broken it might not come out easily. DO NOT FORCE IT. If it does not come out easily, remove your slave cylinder and try to pull it out from the other side.
If the pushrod is not broken, take it out and put it on a VERY flat surface. Roll it and see if it wobbles. If it wobbles, the pushrod is bent.
You should also see two small O'rings on the pushrod. These o'rings prevent the oil from leaking to the basket or the slave. If they are missing or broken, replace them. Also make sure they are not stuck in the passageway between the the slave cylinder to your drum. Some times broken o'rings can get stuck in the passageway preventing the pushrod to move freely.
Also check the throw-out bearing on the pressure-plate. It should spin freely. Some times the bearing can seize and when that happens, a lot of strange things can happen that are hard to explain.
When putting the parts back together, put the o'ring on the grooves of the pushrod first, lube the pushrod with some engine oil before passing it through the passageway or you will damage the o'rings. It is bettet if you put the pushrod from the slave side. The o'rings will have less distance to travel that way. Also put some antiseize lube on the end of the pushrod where the pin that goes into the pressure-plate is located.
When putting the pressure-plate back on the clutch plate stack, line up the two-arrows on the pressure-plate with one of the drum posts that has a groove on it. Failure to do so will cause the pressure plate not to press against the plates and ride on the drum grooves causing the clutch not to work and potentially damaging some parts. When you tighten the clutch spring retaining screws, be VERY careful. They only take 5 Nm. They can snap if you put too much torque on those bolts. Use a handle similar to a screw driver with proper bit that fits the Allen head of those bolts. It will be very hard to over torque them using a scre driver type tool. A ratched wrench can easily apply too much torque and break those bolts. BTW, because of the direction of rotation of the clutch drum, those bolts will hardly ever get loose and only want to tighten when the engine is running.
Try the above, it that does not solve your problem, post another message and we will go from there.
-Fariborz
