after a long old rebuild the old girl has now got clutch problems.. after starting the clutch won`t engage at all. i`ve put the bike on the stand and put it in gear every thing fine but but no response from the clutch. tried to adjust with every posible adjuster but to no look. any ideas guys ????? cheers daz
Did you loose a part from the clutch ? Maybe the ball bearing that goes in at the end of the pushrod ? There is also an adjuster on the clutch itself. Is it assembled correctly ? Something is wrong somewhere, you might have to take it apart and compare it to a parts diagram.
For a TE610e 2000. Looks like you have a plane Te?? Disconnect the clutch cable from the handlebar lever. Then loosen the lock nut on the adjuster screw in the middle of the clutch and adjust the screw in the center to set the distance from the outside of the clutch lever on the engine to the outside of the cable stay mounted on the engine by the starter. This distance is 5 7/16" to 5 1/2". Push the engine clutch lever towards disengagement till it stops to measure. Hook the cable back up and adjust to 1/16" to 3/16". Check the clearance between the throw out bearing and pressure plate. The dimension is 1/16" between the throw out bearing and the clutch pressure plate. You can bend a 1/16" dia. wire to make a measuring tool here. A new clutch will need a full 1/16" and older, worn in clutch, can live with a little less than 1/16". Less will yield more disengagememt and vice versa. Another way to do this is to place the 1/16" wire between the throw out bearing and pressure plate, then make the 5 7/16" to 5 1/2" adjustment. See page D.25 in the service manual. For a Te 610, disconnect clutch cable, Lock the clutch pressure plate to the clutch hub by alining slots in each and insert screw driver, loosen lock nut and adjust the adjuster screw in the middle of the clutch to achive 1/8" to 13/64" ( .12 to .2" ) free play of the engine clutch lever. Measure by the outside end cable slot. i can scan manual pages and send to you if you need them.
