Help! T595 Stuck Clutch

Discussion in 'Technical Help' started by Guztaw, Jan 26, 2020.

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  1. Guztaw

    Guztaw New Member

    Jul 12, 2019
    19
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    Sweden
    #1 Guztaw, Jan 26, 2020
    I recently performed and now the clutch won't disengage (when putting the bike into gear it jumps and stalls). I have tried to get it unstuck with some simple tricks I found on YouTube but nothing worked. I tore the bike down again, picked the clutch plates off and put them in an oil bath, making sure every plate got coated well. I later assembled it back together and the clutch still doesn't work. I have gone trough the mechanic book several times and everything is fitted the right way. Any suggestions?

    Thanks

    3F4408AF-ACEB-48D5-AC85-80D1A8BED2B9.jpeg
     
  2. Rocker

    Rocker Elite Member

    May 1, 2016
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    #2 Rocker, Jan 26, 2020
    Broken / frayed cable?
     
  3. Guztaw

    Guztaw New Member

    Jul 12, 2019
    19
    3
    Sweden
    #3 Guztaw, Jan 26, 2020
    Wish it was that simple... The cable is intact and correctly adjusted!
    Cheers
     
  4. Gladtobebackontwowheels

    Gladtobebackontwowheels Noble Member

    Nov 23, 2019
    398
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    Dover. UK
    #4 Gladtobebackontwowheels, Jan 26, 2020
    If it's not disengaging the problem must be with the actual lifter shaft assembly surely??
     
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  5. Sprinter

    Sprinter Kinigit

    Aug 17, 2014
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    #5 Sprinter, Jan 26, 2020
    100066554-0-2.jpg
    Are you loading the spring when you assemble part 19?
     
  6. Guztaw

    Guztaw New Member

    Jul 12, 2019
    19
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    #6 Guztaw, Jan 26, 2020
    Very good tips! The clutch feels and looks to be functioning properly! When I release the clutch lever it snaps back like it should. If I look down the oil filling hole I am able to see the clutch move...
     
  7. Sprinter

    Sprinter Kinigit

    Aug 17, 2014
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    #7 Sprinter, Jan 26, 2020
    How was this discovered, had you been working on it? Had it been sitting?
     
  8. Gladtobebackontwowheels

    Gladtobebackontwowheels Noble Member

    Nov 23, 2019
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    #8 Gladtobebackontwowheels, Jan 26, 2020
    .....and what does "performing" involve?? Could you have broken something internally?
     
  9. Guztaw

    Guztaw New Member

    Jul 12, 2019
    19
    3
    Sweden
    #9 Guztaw, Jan 26, 2020
    In the end of last summer my clutch springs broke. I have done alot of maintenance this winter including dropping the motor and replacing seals. During this time the clutch sat dry for about 3 months... Now that I've got it all together I tried going for a shake down ride around the block and I couldn't even get rolling. When having the back wheel raised off the ground I can shift into gear (the gearbox is OK). I have had the clutch apart three times now and still no progress...

    Cheers
     
    • Like Like x 1
  10. Guztaw

    Guztaw New Member

    Jul 12, 2019
    19
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    #10 Guztaw, Jan 26, 2020
    Typo, should be: "recently performed a clutch replacement".
     
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  11. Sprinter

    Sprinter Kinigit

    Aug 17, 2014
    5,995
    1,000
    uk
    #11 Sprinter, Jan 26, 2020
    Clutch does not engage at all

    • Binding in linkage or cable due to corrosion
    • Bent linkage
    • Seized slave cylinder
    • Seized throw out bearing
    • Failed pressure plate diaphragm
    • Failed friction plate
     
  12. Gladtobebackontwowheels

    Gladtobebackontwowheels Noble Member

    Nov 23, 2019
    398
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    Dover. UK
    #12 Gladtobebackontwowheels, Jan 26, 2020
    Sorry, a bit of an aside, but have you removed the sump and made sure it is completely clear of bits of broken spring? I mention this because my bike suffered broken springs and a bit of spring found it's way into the oil pump shattering it and requiring an engine strip!
     
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  13. Guztaw

    Guztaw New Member

    Jul 12, 2019
    19
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    Sweden
    #13 Guztaw, Jan 26, 2020
    Hi! Yes! I dropped the motor out of the frame and made sure the gearbox was not damaged! While doing that I removed fragment of broken springs!
     
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  14. Callumity

    Callumity Elite Member

    Feb 25, 2017
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    #14 Callumity, Jan 26, 2020
    That is the logical conclusion. The problem is in the actuator.

    It sounds like the vertical rod is not engaged with the lifter pin. The clutch lever will operate under the resistance of the cable spring (albeit more easily) but the clutch will remain clamped by its own springs. Having it apart three times (we’ve all been there!) simply means repeating the same mistake/oversight......
     
  15. Gladtobebackontwowheels

    Gladtobebackontwowheels Noble Member

    Nov 23, 2019
    398
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    Dover. UK
    #15 Gladtobebackontwowheels, Jan 26, 2020
    Aye, but he said the clutch feels normal and he can see the plates move when looking down the oil hole, so a bit stumped really.
     
  16. Guztaw

    Guztaw New Member

    Jul 12, 2019
    19
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    Sweden
    #16 Guztaw, Jan 26, 2020
    As the kind sir "gladtobebackontwowheels" said: the clutch operates like normal and I'm able to see the plates move when looking down the oil hole. Thanks for the input tho! I'm out of ideas...
     
  17. Callumity

    Callumity Elite Member

    Feb 25, 2017
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    #17 Callumity, Jan 26, 2020
    How confident are you that the plates were re-fitted in the right order?
     
  18. Guztaw

    Guztaw New Member

    Jul 12, 2019
    19
    3
    Sweden
    #18 Guztaw, Jan 26, 2020
    With the new clutch I ordered I got new plates, installed them in the same order they came in. Today I tried the old plates in the same order they came out. (Yes, the first and last plates are the correct ones) Even if I I misplaced a few plates the clutch would still work right? Might slip or something but wouldn't be completely faulty?
     
  19. Callumity

    Callumity Elite Member

    Feb 25, 2017
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    #19 Callumity, Jan 26, 2020
    The steel plates may be slightly different thicknesses and not interchangeable and are the tabs on the outer plate offset to the rest? I am not familiar with your particular clutch but they are pretty similar.
     
  20. Callumity

    Callumity Elite Member

    Feb 25, 2017
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    Nr Biggar
    #20 Callumity, Jan 26, 2020
    And a completely wild thought....... are you sure it is not the ignition safety lock out? Trying to engage gear with a defective switch will give you a jolt and a stall.......
     
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