Question about 1977 Suzuki GS 400 E

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The clutch will not release, the clutch handle will not spring back. What should I look for?

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First check and make sure the cable is not binding,Then check the clutch disengagement arm or the engine,you can try and move it to test the spring with some channel locks or similar pliers,If it moves freely with no spring back,You may need a new throw out bearing.


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Posted on May 13, 2009

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Clutch handle hard to pull


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My Nissan 95 sentra clutch had crunched and pedal would not spring back, found that clutch cable had snapped, replaced this and now my clutch pedal is still not 100% springing back, it springs back en


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Remove the cable and check operation of the pedal and spring mechanism.
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Tri z I havnt started my tri z since sept and I started and put in gear and in jumped and stalled. I started againg with clutch handle pullled in and started and it jumped and i didnt let it stall drove...


I had a Tri Z, and every time it sat the clutch stuck. I'm not exactly sure why your clutch won't disengage when you tighten the springs-I do know that the springs MUST be tightened to where the bolts bottom out for it to work. I do also suspect that running it with the springs loose has burned what was left of the clutch. The basket and inner hub grooved could be an issue. It would depend on how bad it's notched. They will normally operate fine with some notching. Filing down the basket is not recommended-you would have to take the exact same amount of material off each finger of the basket for it to work properly. I've done this only to get it running while waiting for a new basket and drive hub to arrive.
The main thing now is to get the clutch to disengage w/ the lever. Take the pressure plate off, and watch for the lifter to mave about 1/8" when you pull the lever. If it's not moving, or is too high, remove the lifter, the round ball behind it and the engaging rod out of the hollow clutch shaft. A small magnet tool works well.It may have gotten past the cam on the cable end of the system. With the rod out, turn the cable actuating lever back to the end of it's slack and reinstall the rod,ball and lifter. You should be able to turn the cable actuating rod with your fingers and watch the lifter come up. You can feel when the rod is in the right position on the cable arm-it should bottom out and lift within the working rotation of the lever. So if you get that working, put what's left of the clutch back together, tighten the springs and make sure it works.You will at the very least need to replace the friction plates in the clutch. The steels should be checked for warpage on a flat surface. If you can get .002 feeler gauge under the warp it's too far gone and they should be replaced as well. Most Yamaha clutches have a first and last friction plate that's a different part number when you order them, be sure to check that when replacing the plates.I'd get new springs as well, they're cheap. Good luck!

Jun 27, 2011 | Yamaha YZ 250 Motorcycles

1 Answer

Tri z started and put in gear and in jumped and stalled. I started againg with clutch handle pullled in and started and it jumped and i didnt let it stall drove it around and shifted gears but was very...


It sounds to me like a part is missing in the clutch assembly. Bear in mind that the first plate installed in the clutch assembly is a cork friction plate, then metal, cork, metal, ect.. You should end up with a cork friction plate. There should be 6 metal plates and 7 cork friction plates. The diagram below is a tri-z 250. Please rate my answer. Thanks! tombones49_199.gif

Jun 27, 2011 | Yamaha YZ 250 F Motorcycles

1 Answer

The clutch will not spring back after you pull the clutch handle


Unhook both ends of your clutch cable if it is binding at all replace it. If the lever on the motor does not go all the way back to riding position (disengaged clutch position). You may have to disassemble the motor to check for a broken spring or damaged clutch engagement mechanism.

Oct 29, 2010 | 2003 kawasaki KX 125

1 Answer

Bought a new Husqvarnia 450 chainsaw and folowed the instructions to fit the chain bar. I found it difficult to take off the clutch cover (the brake had not released fully). I cannot get the clutch cover...


I guarantee you are not the first to experience this. In the future if the clutch cover is difficult to remove please do not!
Reset Chain Brake
Immobilize the clutch cover (blocks of wood on a flat surface to protect the finish) in a vise or with a large C-clamp to a work surface.

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Use pliers or a crescent wrench and rotate it clockwise until it latches open. This will require some force. A slight modification reported in a testimonial to the above method follows;
" Thanks for the help. I took your answer and modified the fix a little. I placed the cover on loosely and then moved the bar handle into the right position in order to engage the spoked wheel, then rotated the handle back until the cover fit right. Thanks, SG " – NameRemoved

If you have more questions or need additional help please reply below and I will get back to you. HTH & Good Luck.
Lou
Thank You for using FixYa.

Jul 14, 2010 | Husqvarna Garden

3 Answers

Wheels lock when self propel not engaged


Hi
a;; you need tp do is loosen the cable slightly to the self drive mechanism

Apr 05, 2009 | Garden

18 Answers

CHAINSAW BRAKE LOCKED ON HUSQVARNA 455 RANCHER HELP PLEASE?


I used applman08's solution. A few pointers:
0. This problem occurs when you take off the side cover while the brake is set. So after you fix this, don't do that again.
1. When removing the clutch, place the screwdriver in the notch next to where it says "off" and tilt the screwdriver down so that when you strike it you are applying a clockwise shock force that is almost horizontal (assuming your 455 is on its side).
2. DO NOT remove the spring! There is a plastic housing that basically holds the brake mechanism in place (secured by 4 screws). If you take that apart, and then take out the spring, you will be learning how the brake works and spending some time compressing that spring and getting it back in. You'll have to come up with something clever to get the spring in depending on tools available.
3. Going back to 1. - get that clutch off, put the side cover back on, getting that brake lever lined up with the very-difficult-to-grab three-toothed mechanism for engaging the spring. Tighten down the side cover, or hold it snug with one hand while you lever the brake handle with the other. You will hear a satisfying snap as the braking mechanism (with the spring I told you not to mess with) resets.
Note: You can probably reset the braking mechanism by manually turning that three toothed gizmo but it's really hard to grab and the brake handle fits it perfectly. The key is you've got to turn that about 60 degrees.
Good luck, this was an annoying problem.

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