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Pin fell out inside housing wen i installed new clutches

Pin fell out lnside housing of 2009 140 put new clutches in

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My 2000 sportster fell over and the clutch lever broke off about half way. I need to put on a new lever but there is no screws or anything to put a wrench or screwdriver on. Just a round pin holding it on....


There is an E-clip on the bottom side of the lever pivot. Take this clip off and the pin slides up and out. The lever comes loose but you need to put some slack in the clutch cable by finding the cable adjuster in the middle of the cable and turning it inwards to get some slack. Readjust by turning the adjuster barrel outwards until you have about a 1/16th inch free travel at the clutch pivot.

Good Luck
Steve

Jul 19, 2011 | Harley Davidson XL 1200 C Sportster Custom...

1 Answer

1994 ISUZ AmigoThe pedal is disconnected...total free play...not


There is a pin that connects the clutch pedal to the clucth master cylinder. It sounds like this pin fell out. It is just a matter of lining up the hole in the master cylinder with the connector off of the clutch pedal. Push the pin in and install a new cotter pin to secure.

Jun 11, 2010 | 1994 Isuzu Amigo

1 Answer

74 honda TL125 with a free play feel in the clutch leaver


On most bikes, there is a rod going down the center of the clutch. The lever on the case pushes this rod in when you squeeze the lever on the handlebar. If the rod going through the clutch will not move, the clutch will not release. It doesn't move very much, maybe a few millimeters. If you cannot remove the rod[you may have to use a magnet to pull it out] then the rod is bent. This could have happened if you assembled the new clutch incorrectly. If the sequence during reassembly was wrong, the disks were jammed. When you squeezed the clutch lever, something had to give. The clutch rod.

Sep 21, 2009 | 2008 Buell Blast

1 Answer

Push in clutch lever play even with new cable on my 74 TL125


It still sounds like that roller ball is missing. Do you have a manual to check for exact location? Yamahas have them on the casing side but not sure about Hondas. It is REALLY easy to drop out without being seen.

Parts in that casing do not usuall "weld" themselves together unless someone has really been abusting the clutch. Could be the clutch spring has lost some tension but no way to tell without comparing it with a new one. If you had a manual or even a friendly dealer you could find out proper specs. for the spring and then measure yours.

Don't just start replacing parts without verifying they have failed. It can just get expensive and not solve anything.

If you have a digital camera, take a picture of the assembly you believe to be seized together and email me at robertlanglois6@sympatico.ca
I will see what I can figure out.

How many hours / km on the bike? Clutch plates may be kaput but you don't mention clutch slipping?

Don't cut the cable yet. If you do, just trim it to about mid adjustment. It is easy to cut a bit more than cut too short! Either way, cutting is a bodge job. Best to find root cause and fix it.

Send me pictures if you can.
Rob

Sep 21, 2009 | 2008 Buell Blast

2 Answers

1998 ford expedition how to install rear spider gears


Find a PICK-your-PART auto salvage and go get a whole rearend for $150 or so. You will be way far ahead. Or submit to the BLUE OVAL (dealership). Sorry no easy fix.

Sep 03, 2009 | 2000 Ford Expedition

1 Answer

How do i replace my clutch kit. i burned it out


ello mate,,first drain the oil out,remove the right side lower fairing,,then remove the wot looks like a large circular engine casing,then remove the bolts with springs holding the clutch plates in,,take off the cover then u will see the plates and metal lookin clutch plates,, now take out the clutch plates one at a time,,,ie take one out then place on the bench,take a metal plate out and place that on top of the 1st plate u took out,and so on,, when u have the new fibre plates,,replace back in the bike as u took the old ones out,,ie, new fibre plate 1st then put a metal friction plate back in from your bench,,then a new fibre plate and so on,,each time u replace the new plate ,chuck away the old one,,wen u have done that ,on the clutch plate cover look at the face of the cover u will see a small arrow head or a dot stamped on the face of it,, that dot should line up with a dot thats stamped on the housing where the clutch plates are,put the plate casing on so that the dots line up ,,put the springs and bolts back on and do them up tight,,then replace the engine casing,,,put your oil back in,,if u have a hydrolic clutch u will have to remove the 3 screws and the clutch piston b4 taking the casing off ,,,to read this it will sound complicated m8,, but wen u start the job itl be quite easy,, take your time tho,,any probs m8 ,shout and il anserw u,, ok,, cheers now

Mar 30, 2009 | 2007 Suzuki GSX-R 600

1 Answer

My yz 250f fells like it has to much compression


check the clutch adjustment also the clutch could be binding or just stuck

Jan 28, 2009 | 2004 Yamaha YZ 250 F

2 Answers

Gearbox from clutch


have you checked the clutch mechanism? for me sounds like the clutch doesn't engage properly or fully rather. Ask your mechanic to check the clutch system fully and check whether it fully engages, or do this check for yourself. Bring car onto a flat surface and shift to 1st while engine being switched off, start it while pressing the clutch (fully down to the floor board) and then release parking break and check for following
whether vehicle is moving
RPM decreases a bit
does engine get loaded and start vibrate or rattle a bit

Jun 07, 2008 | 1987 Peugeot Liberte

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