My bike ran out of gas one day, so I held the clutch in while I coasted to the gas station. After filling up, I started bike and went to release bike into first and it didn't budge and the engine died. It was like trying to start out in 4th gear or something, but the bike didn't budge.

Any idea on what the problem is, and what I need to do to fix it? It is getting warm and I want to ride!

Sound like you locked up something somehow. You did not say how long you "coasted" to the gas station, but you should have put the bike in neutral instead of holding the clutch.


With the engine off...

If you put the bike in neutal now, will it roll forward easily?

Does pulling in the clutch while in gear also let the bike roll ?

Kinda sounds like you might have burned up a clutch plate or two.


KM

I might have put it in neutral, but it was last year and my memory is fuzzy. I coasted less than 1/4 mile.

It rolls in neutral, but I cant get it into gear. There were no sounds, or anything that seemed to be wrong other than the fact that it won't get into gear.

Any ideas how I could diagnose this a little better for you?

well all of what you have said so far seems to point to a frozen up clutch..and not one that is slipping.
The worst case scenerio would be a broken shift fork, but I think to start out you should take the clutch apart and make sure it is OK.

See if the plates seperate when you pull the clutch lever.

Before you do this adjust the cable , it is possible the cable just got stretched and needs an adjustment...but I would still take the clutch apart if adjusting the cable didn't fix it right off.

From what you said also it sounds like the bike has sat for awhile. It does run ok although you can't get it in gear right?


KM

Yep, it runs fine. I adjusted the cable earlier, so I'll take the cover off to see if pulling the clutch will seperate the plates.

How difficult is it to give the whole clutch system an overhaul; replacing what needs to.

How difficult is it to give the whole clutch system an overhaul; replacing what needs to.

Actualy it is fairly easy. I have some photos here:
http://tinyurl.com/pvv5p3

Sorry can't find the write up but if you get to that point there are many here that can answer your questions. I went with a set of Kevlar plates I bought here:
http://tinyurl.com/e3x6h

This came with heavier duty springs. I suggest going this route as opposed to just replacing the friction plates and re-using the stock springs.

Other parts needed would be the clutch cover gasket, this available at your dealer for around 8 bucks.

I also suggest either replacing the stock drive plates (the ones with no friction material on them, just plain metal) or sanding them carefully with 320 grit on both sides.

Of course replace any that burned or warped.

You need to soak the friction plates in clean engine oil overnight, but that is about as complex as it gets. A long dental pick is handy for pulling the plates out of the hub.

Anyone got anything else to add?


KM

Thanks for the info man. You've been a big help. Im sure I'll have more questions once I get everything pulled apart. Going to try and tackle this in the next few days. I read about some special way that I need to re-install the plates. Any idea about that?

I read about some special way that I need to re-install the plates. Any idea about that?

not sure about that, I just noted how they all came off and simply reversed the proceedure putting them back on. For the life of me I can not remember which type of plate goes on first, but you'll find that out as soon as you take it apart.
The very last plate you put on is supposed be offest from the others by one space on the outer hub. You too will see this when you take the plates off. I actualy did not do that upon reassmbly and never had a problem.

I used blue loctite on the spring bolts. If the bike is on the sidestand when you work on it (suggested) you do not have to drain the oil.

A good 6 point 8mm? socket is needed to remove the cover.

Sorry if a bit sketchy on details but it's been about 5 years since I did it.


KM

I am sure this is not the problem, but did you raise the stand???

Thanks for the info man. You've been a big help. Im sure I'll have more questions once I get everything pulled apart. Going to try and tackle this in the next few days. I read about some special way that I need to re-install the plates. Any idea about that?

http://www.webng.com/jthill/graphics/VN750/c1.jpg

Note:
Install the first seven friction plates fitting their tangs on the plates in the Main Grooves (A)green) in the clutch housing.
Then install the last one fitting it's tangs in the Secondary grooves (B)Pink).

I am sure this is not the problem, but did you raise the stand???

No, good thinking, I just pondered this and came back to re-read his symptoms...

Are you saying you can't get the bike into gear when it is running or when it is not running or both?

The reason here there is a switch in the sidestand as Nite pointed out, and there also is a switch in the clutch lever housing too. If the Sidestand switch is messed up, or the stand is down, when you try and put it into gear it will die.

The switch in the clutch..and someone correct me if I am wrong, allows you to be in gear with the clutch in...even if the stand is down. But if you release the clutch, the bike will die.

From his discription I took it to mean he can not get out of neutral at all , bike on or off....


KM

No, good thinking, I just pondered this and came back to re-read his symptoms...

Are you saying you can't get the bike into gear when it is running or when it is not running or both?

The reason here there is a switch in the sidestand as Nite pointed out, and there also is a switch in the clutch lever housing too. If the Sidestand switch is messed up, or the stand is down, when you try and put it into gear it will die.

The switch in the clutch..and someone correct me if I am wrong, allows you to be in gear with the clutch in...even if the stand is down. But if you release the clutch, the bike will die.

From his discription I took it to mean he can not get out of neutral at all , bike on or off....


KM

That was my first thought (side stand switch) til I re-read his first post. Sounds more like it won't go into gear, but it might be how he's describing it???

It doesn't seem like the clutch is doing a thing. It's rough going into first while sitting still with bike running. then I go to release clutch, and the bike dies.

What is the sidestand switch?

My bike is an 86, and it has 12k on it. Doubt that helps any.

It doesn't seem like the clutch is doing a thing. It's rough going into first while sitting still with bike running. then I go to release clutch, and the bike dies.

What is the sidestand switch?

Ah, think we have a winer. If the bike does not die until you let go of the clutch it does sound like you have a bad sidestand switch.

If you look at your side stand you will see it. You will see a tiny plunger get pushed in when the sidestand is moved. Hard to remember , but you can see it alot easier than me as you have the bike there to look at.

Sometimes the plunger thingy is just stuck, and a spray of WD40 will clear it up. Sometimes it is just bad.

Most who have bad ones simply remove them, but I can't remember if the circuit needs to be open or closed for it to be bypassed.

Am sure someone more electronicly savy will fill you in.

KM

So, how come I can get it into first gear without the clutch working properly. Definately not questioning you, I just don't understand the way it works.

1. start bike
2. pull clutch
3. put is first (is not real smooth, sounds like it is forced)
4. release clutch and bike dies.

Oh, by the way. The bike is not with me right now. You were probably wondering why I dont just go look at the "plunger thingy". I just moved, and the bike is still on the otherside of town. Just trying to get some ideas before I get started.

So, how come I can get it into first gear without the clutch working properly. Definately not questioning you, I just don't understand the way it works.

1. start bike
2. pull clutch
3. put is first (is not real smooth, sounds like it is forced)
4. release clutch and bike dies.

1. start bike
a. raise stand

1. start bike
a. raise stand

Look man you're funny, but i'm looking for help.

Look man you're funny, but i'm looking for help.

I hope you get it fixed. There is nothing harder than finding a bad safety switch.

Oh, by the way. The bike is not with me right now. You were probably wondering why I dont just go look at the "plunger thingy". I just moved, and the bike is still on the otherside of town. Just trying to get some ideas before I get started.

No problem. I would however start with the easy crap before tearing the clutch down.

You know now where to look and what to look for. If it is just the switch you have saved some money and alot of time.

If I remember right, when the sidestand is down, it pushes the little plunger in, so it is very possible it is just stuck, try pulling it out with a pair of needle nose after raising the stand.

I could Bet the bike won't die when you let out the clutch then.......


KM

I have to agree that the side stand switch is the problem!! :beerchug:

Any news LGS?