Clutch

[Nightbiker07]

ok, i tore this tranny apart today (case ran out of oil)
so i got the bearings replaced, and i put it all back together and the clutch wont disengage. i pulled the basket apart and made sure the plates werent locked together, the clutch lever feels just like it did before the teardown, but it doesnt disengage. it only releases about 1/3. i am clueless.

its not a trike, but this forum gets way more traffic than the bike section, and i am desperate for answers. anything i should look for/check?

[Nightbiker07]

i cant find a service manual either...its a newer kawi kx80. between 98 and 01

[ATC-Eric]

Do you have it adjusted correctly?

[Nightbiker07]

the lever isnt all sloppy. i actually tried tightening the cable to where it is at about 1/2 pull before pulling the lever. no change whatsoever.

[ATC-Eric]

Not with the cable, with the clutch arm itself. If you took it all apart, and didnt put it together correctly again, the clutch will act up.

[Nightbiker07]

true. but i had it apart a few times, and put it together differently and nothing :/

[1upfront]

Did you loose the ball bearing that goes on the end of the clutch actuator rod?

[Huffa]

Is it possible your basket may be grooved and holding the plates closed, like this one?

Not sure if you knew to look for that or not ?

If they are but not too deep, they can be filed smooth again otherwise another basket is in order.

I'd say this one is too deep for repair or borderline for sure.

The clutch worked fine though before you pulled it apart ?

[Nightbiker07]

yeah, the clutch was fine before the teardown.

good news though, i fixed it.
a WASHER was on the wrong side of the basket assembly, and when it was tightened together, it was binding.

it really baffled me because i could feel the plates separating when the lever was pulled (finger into oil fill hole)