another stuck clutch

mobilyte · Post by **mobilyte** » Tue Jun 29, 2010 7:34 pm

my 65 cb77 had a stuck clutch from sitting since 1974

took the clutch apart, replaced a friction disk with missing tabs, cleaned everything with a scotchbrite pad and lacquer thinner, reassemble, snapped off a clutch spring bolt!

redo everything, replace the clutch hub, reassemble...still stuck.

take it all apart again, pre-oil all the disks/plates this time. with the engine cover off, i pull the clutch cable while pressing in the outer oil guide. i can see the thick plate separating from the 1st friction disk and 1st thin plate (thanks to the wire retainers), but the remaining disks/plates stay clumped.

i've check everything several times...the orientation of the thick plate, the order and # of disks/plates, the lifter rod joint/spring/tiny pin/oil guide, etc...just cant seem to get the clutch to disengage.

did i miss something? i thought the spare friction disks i used might be too thick, but they all measured within spec (~4.9mm).

e3steve · Post by **e3steve** » Wed Jun 30, 2010 2:02 am

Did the ball fall out from the lifter thread at the other end if the rod?

brewsky · Post by **brewsky** » Wed Jun 30, 2010 5:53 am

Did you measure the thickness of the frictions you removed from the hub?
Sounds like you may have frictions too thick for the hub they are in.

mobilyte · Post by **mobilyte** » Wed Jun 30, 2010 2:07 pm

after posting this last night, i took apart the left side cover again. by the time i got back to the computer, ed asked me to call him and we went over everything.

operating the clutch lever with the left cover off, i could see the pressure plate moving. the first friction disk would separate from the thick plate, the second disk would also separate along with the first thin plate. but, again the remaining disks/plates would just clump.

as ed and i chatted, i zip tied the clutch lever and worked the disks/plates apart by hand. i put her in 1st gear (engine not running) and was able to turn the rear wheel with some effort. by the time i got it back together and filled with oil, the clutch would not break free again.

steve - the correct ball is present between the right cover adjuster and lifter rod

brewsky - i'm going to have to disassemble again and closely examine these disks/plates along with all of my spares

brewsky · Post by **brewsky** » Wed Jun 30, 2010 4:56 pm

The reason I asked about the friction plate thickness is my spec book shows 2.9 - 3.0mm for new and 2.5mm for wear limit.
There was evidently more than one spec used (my old fiber plates were 3.9mm) and the good ones I got from LM were 3.0mm if I remember correctly.
Also more than one other basket. Also different length springs(although that should not affect the release)
Also need to check for warped steels and/or notched basket fingers while it is apart.
Whatever the problem is , LM will have the answer.