Clutch change - no tension on pull-rod - Triumph Forum: Triumph Rat Motorcycle Forums
Tiger 800 - 800XC Mods & Workshop Workshop and technical talk for the 800 - 800XC Tourer - Adventurer Tigers

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post #1 of 10 (permalink) Old 01-08-2017, 05:29 PM Thread Starter
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Clutch change - no tension on pull-rod

Howdy folks,
Today I attempted a clutch change on my '14 800XC, but I've hit an issue I don't understand. With everything reassembled, there is no resistance on the clutch handle. The clutch arm by the cover is rotating back and forth, but there is no pressure from the clutch assembly. After staring at the thing for a couple hours, I'm assuming the pull-rod (or "clutch lifter piece" according to bike bandit) isn't actually disengaging the clutch by pushing on the pressure plate. I have tried reassembling this thing a hundred times to make sure it's right to no avail. The pressure plate bearing looks fine. The pull-rod rotates freely and has free-play to move in and out. Perhaps it has too much in-and-out free play, but the only thing that would make this different from before is the thickness of the clutch pack, which I have measured at almost exactly 42.00mm.

Any ideas?

John
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post #2 of 10 (permalink) Old 01-09-2017, 10:42 AM
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Originally Posted by jovol View Post
Howdy folks,
Today I attempted a clutch change on my '14 800XC, but I've hit an issue I don't understand. With everything reassembled, there is no resistance on the clutch handle. The clutch arm by the cover is rotating back and forth, but there is no pressure from the clutch assembly. After staring at the thing for a couple hours, I'm assuming the pull-rod (or "clutch lifter piece" according to bike bandit) isn't actually disengaging the clutch by pushing on the pressure plate. I have tried reassembling this thing a hundred times to make sure it's right to no avail. The pressure plate bearing looks fine. The pull-rod rotates freely and has free-play to move in and out. Perhaps it has too much in-and-out free play, but the only thing that would make this different from before is the thickness of the clutch pack, which I have measured at almost exactly 42.00mm.

Any ideas?

John
I haven't personally done my clutch yet on my Tiger, but I will be doing so fairly soon I'm sure. I read and copied the clutch section of my Service Manual to prepare for it. It has the proper stackup order and thicknesses in it.

Looking at the breakdown, the pull-rod obviously has a T-profile on the end to engage the clutch arm. Are you sure that the arm is engaging that slot properly when installing the cover?

I can PM or email you the clutch section of the Service Manual if that would help.
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post #3 of 10 (permalink) Old 01-09-2017, 01:26 PM
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Clutch change - no tension on pull-rod

I have to ask... are you guys doing huge distances on your bikes and lots of stop/start? I wouldn't expect to do anything to a bike clutch before 50,000 miles at the very least!
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post #4 of 10 (permalink) Old 01-09-2017, 04:16 PM Thread Starter
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No, I've not done huge distances. I did buy the bike used and it has 12k miles on it now. I've been feeling some weirdness in the bike, and I'm thinking of taking this bike to south america later this year, so I figured this was a good chance to look at the clutch and give it a refresh to stave off issues on the trip.

Thanks for the input XYooper906. I have a PDF of the service manual (taken from here: https://github.com/tonymorris/800xc/...ter/manuals.md). I've verified the clutch pack thickness multiple times. I made sure to install the anti-judder washer, and the anti-judder "spring" (with the tall part in the middle). I *think* I've installed the clutch cover correctly such that the clutch arm is engaging the pull-rod... but maybe not?
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post #5 of 10 (permalink) Old 01-09-2017, 05:00 PM
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I have to ask... are you guys doing huge distances on your bikes and lots of stop/start? I wouldn't expect to do anything to a bike clutch before 50,000 miles at the very least!
I'm currently at 30K, no real signs yet that it's imminent. I do a fair amount of off-road riding, but I think I'm fairly easy on it in those and road riding situations. It seems that there is a wide range of mileage that people have ridden before replacing the clutch. I am just anticipating it to happen sometime soon. But I won't replace it until it needs it.
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post #6 of 10 (permalink) Old 01-10-2017, 11:38 AM Thread Starter
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So I made the clutch pack a bit smaller, then I took up all the slack on the clutch cable adjuster, plus extra such that the second nut isn't on the threads, and now it kinda works. Perhaps a previous owner put a weird length cable on the bike, I'm not sure. I'm going to bring it to the dealer tomorrow and see what they say.
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post #7 of 10 (permalink) Old 01-11-2017, 06:04 PM
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Is there a "ball bearing" that goes between the push rod and the clutch basket? I know Yamaha has this little sucker.

MSF RiderCoach. Retired!
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post #8 of 10 (permalink) Old 01-12-2017, 12:15 AM Thread Starter
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Yeah there's one of those between the pressure plate and the pull rod, part 21 in this pic:
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post #9 of 10 (permalink) Old 01-13-2017, 06:52 PM Thread Starter
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Turns out I'm a bit of an idiot. Apparently one of the discs has a slightly larger inner diameter, and that's supposed to be the inner plate. The larger diameter is so that it doesn't touch the washer and Belleville spring. Since I had the wrong disc in first, it was pushing the whole clutch pack out too far.

Oh well, we all gotta learn somehow! Thanks for the help everyone.
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Last edited by jovol; 01-13-2017 at 07:34 PM.
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post #10 of 10 (permalink) Old 01-13-2017, 11:18 PM
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Turns out I'm a bit of an idiot. Apparently one of the discs has a slightly larger inner diameter, and that's supposed to be the inner plate. The larger diameter is so that it doesn't touch the washer and Belleville spring. Since I had the wrong disc in first, it was pushing the whole clutch pack out too far.

Oh well, we all gotta learn somehow! Thanks for the help everyone.
"An expert is a man who has made all the mistakes which can be made, in a narrow field." Niels Bohr

Thanks for taking one for the team! ;-)
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