Rocket 3 2006 Clutch Problems.

[Matt15]

Hi Folks

Approximately 6 months ago i parked up my 2006 Rocket 3 in the garage to do couple of things to it including painting the tank and fenders and also changing the handle bars. Long story short, after changing out the handles bars I realised I needed a different length clutch cable. So I purchased a clutch able and installed it. I followed advice from these forums and made sure I had clocked the clutch arm correctly with the dots lining up, also ensured i had free play in the clutch lever. So after I'd installed the clutch cable and bars I started the bike up, pulled the clutch in, and realised that the clutch was not engaging. I'd put it in first gear and it would stall. I checked the kick stand and ensured it was up. But it definately felt like the bike stalled from no engine load and not an electrical stall.

So I thought it might have been the clutch pin that sits in the basket as I Read many times. I pulled the clutch cover and discovered that the pin and the clutch cover shaft appear ok.

I'm stumped as to what the issue is? One thing I noticed is that the clutch pin in the clutch basket seems to have in and out free play. Approx 6mm. Is this normal?

Also there was zero issues with clutch functionality and zero clutch issues in general before parking the bike up.

 

[ozrider]

If your confident all clearances are ok then the plates are probably stuck together

happens to mine when parked for a few weeks and not used, just hold clutch lever in and aim down the driveway and hit the starter button, keep holding lever in when it fires up and blip the throttle a few times when heading down driveway and it frees up

 

[Matt15]

If your confident all clearances are ok then the plates are probably stuck together

happens to mine when parked for a few weeks and not used, just hold clutch lever in and aim down the driveway and hit the starter button, keep holding lever in when it fires up and blip the throttle a few times when heading down driveway and it frees up

Appreciate your Reply. I will most certainly give that a go. I probably should have tried it before I pulled the clutch cover. Though whilst I have it apart I want to make sure it's all alright before I put it back together.

 

[Matt15]

Hi Folks

Approximately 6 months ago i parked up my 2006 Rocket 3 in the garage to do couple of things to it including painting the tank and fenders and also changing the handle bars. Long story short, after changing out the handles bars I realised I needed a different length clutch cable. So I purchased a clutch able and installed it. I followed advice from these forums and made sure I had clocked the clutch arm correctly with the dots lining up, also ensured i had free play in the clutch lever. So after I'd installed the clutch cable and bars I started the bike up, pulled the clutch in, and realised that the clutch was not engaging. I'd put it in first gear and it would stall. I checked the kick stand and ensured it was up. But it definately felt like the bike stalled from no engine load and not an electrical stall.

So I thought it might have been the clutch pin that sits in the basket as I Read many times. I pulled the clutch cover and discovered that the pin and the clutch cover shaft appear ok.

I'm stumped as to what the issue is? One thing I noticed is that the clutch pin in the clutch basket seems to have in and out free play. Approx 6mm. Is this normal?

Also there was zero issues with clutch functionality and zero clutch issues in general before parking the bike up.

I'm also trying to fully understand how the clutch pin and shaft work (sorry I'm still sorta new to these).

My understanding, after watching a video, is that the shaft as it rotates catches the button (pin). This pulls the button outward thus engaging the clutch. Please correct me if I'm wrong.

What I can't understand is that the clutch button has 'In and out' free-play. I'm not sure if this is normal or not? I Removed the spring from the clutch cover shaft and loosely bolted the clutch cover on to see if there was any resistance to rotating the shaft and there was zero resistance. Is this normal without the spring?

I'm also considering doing the warpspeed spring (external) mod while I have the cover off.

Please share any advice.

 

[Kevin frazier]

Play in/out you stated 6mm is normal ( i get closer to 3mm but you may have old style parts, thin lifter piece, wavy washer, not sure if your bike has been updated lifter piece, but freeplay is normal in the lifter piece pulling pushing in out it should move, yes.

 

[Matt15]

Play in/out you stated 6mm is normal ( i get closer to 3mm but you may have old style parts, thin lifter piece, wavy washer, not sure if your bike has been updated lifter piece, but freeplay is normal in the lifter piece pulling pushing in out it should move, yes.

Sorry, I remeasured the free play and it's about 3.5mm.

 

[Kevin frazier]

Above you said you had freeplay at handle, that freeplay needs to be in the 2 to 3 mm range. When you had cover off did you pull clutch pack and check it?

 

[Matt15]

Above you said you had freeplay at handle, that freeplay needs to be in the 2 to 3 mm range. When you had cover off did you pull clutch pack and check it?

The cover is still off. I haven't checked the clutch pack as I'm not sure what to look for or what to do?. I'd be very surprised if there was any issues though as the clutch ran perfectly fine before parking it up for 6 months.

 

[Sparky59]

The shaft in the cover is the cam action that pulls the lifter piece forwards, which pulls the clutch basket cover with it forward then separates the clutch plates causing slippage of the clutch plates. inspect lifter shaft ....ie: rounded edges on lifter shaft is wear( that part that rubs and pulls the lifter piece forward)
If cover on correctly, you will feel resistence on the outside lever...it takes small moves to catch the lifter piece with the rod in cover.

 

[Matt15]

The shaft in the cover is the cam action that pulls the lifter piece forwards, which pulls the clutch basket cover with it forward then separates the clutch plates causing slippage of the clutch plates. inspect lifter shaft ....ie: rounded edges on lifter shaft is wear( that part that rubs and pulls the lifter piece forward)

Appreciate the Replies Folks. I have a feeling that possibly the clutch pack is stuck from not being ridden for 6 months as ozrider stated. I think I should reinstall the clutch cover and adjust the clutch cable and lever correctly. Then possibly try ozriders idea or put the bike in gear (whilst turned off) with the clutch pulled in and rock it back and forth to ensure the clutch is free.

I found that prior to removing the clutch cover and lever, the external arm would get to a point/ angle and go no further. It left like if I pulled it forward harder something would break. I have a feeling though if it was pulled forward beyond this point then that would release the clutch plates enough to disengage.