Bevel Gear/ Clutch Release Problems
Okay so quick backstory. I did the engine tilt on my bike to replace a stator & rotor and I am currently slapping everything back together.
I have read through all the posts about people having problems installing the bevel gear and then having no tension on their clutch release lever. Well I have uninstalled and reinstalled this thing about two and a half dadgum times now and can’t seem to get this thing right.
The first time I installed it I definitely heard a loud “pop” when I was tightening down the bevel gear bolts. I prayed it was nothing big and kept installing it. After I had gotten all the bolts tightened back down the clutch release lever would not budge at all. I figured whatever the clutch push rod sits against in the bevel gear housing was stuck too far out So I took it off again and moved the lever till the “thing the clutch rod sits against” was in it’s lowest position.
Then I reinstalled the bevel gear and now the clutch release lever spins with NO tension in either direction for a lot of degrees and then there will be smidge of resistance (like the shaft finally hits something) and then it slips past it and spins with no tension again in either direction. It just “doesn’t feel right”.
This is how I think it works: When you pull the clutch lever at the handle it pulls the clutch release lever which turns the release shaft and the little splines at the top of the shaft push against the clutch push rod, and then what happens??? Is it possible I messed something up on the other end of the clutch rod, and that is why I am getting no resistance??
The Kawasaki manual made it seem like all of this should have been so easy….but I feel like I am missing the secret sauce of how this works, and am now worried I broke something.
2002 Kawasaki Vulcan 750
1979 VW Bus/Westfalia