hello all, rebuilt the clutch on my 89 fj and am having a problem with it releasing when I pull in the clutch lever. This only happens when it sits for a day. I replaced the fiber discs and plates, the diaphragm spring and clutch boss,rebuilt the master and release cylinder.I have also checked push rod travel with the clutch cover removed and it seems good. What happens is when I roll her out for the day I have too warm her up good then shut her down put it in gear and rock the bike back and forth with the lever pulled in till the plates release. Is this just because everything is new and will free up as it breaks in. :ireful:
Did you replace using OEM or after market parts? Some after market fiber plates stick. Did you soak the fiber plates over night in oil? How many miles do you have on the new parts?
Should be able to rock it cold and break them loose, then start it and go normally.
It's a normal thing with a wet clutch, though it should be a very mild thing. Aftermarket fibers have been known to be really bad about sticking. The only other thing I'd suggest would be ensuring that the outer basket's fingers aren't worn, as they eventually develop mild notches which can cause it also.
OEM clutch parts and decent oil usually solves things.
Quote from: FJmonkey on May 14, 2011, 10:18:10 AM
Did you replace using OEM or after market parts? Some after market fiber plates stick. Did you soak the fiber plates over night in oil? How many miles do you have on the new parts?
I used all OE parts, I did not soak them overnight and it has about 1000 miles on it since being rebuilt. I have disassembled the clutch to check if I missed something but it looks good .[I do have a manual] I also engaged the clutch lever and the plates are definitely released.
If everything is good then you need to lap it in with a couple of burnouts and a few 8000rpm full power gear shifts.
another trick is to shift from 1st to 3 under full power and slip the clutch.
before you put it all back together take a file to the steels and make sure you don't have any high spots and soak the fibers.
using a synthetic oil will help with the sticking as well .
and like Andy B said check your basket.
Quote from: Mark Olson on May 14, 2011, 11:34:55 AM
If everything is good then you need to lap it in with a couple of burnouts and a few 8000rpm full power gear shifts.
another trick is to shift from 1st to 3 under full power and slip the clutch.
before you put it all back together take a file to the steels and make sure you don't have any high spots and soak the fibers.
using a synthetic oil will help with the sticking as well .
and like Andy B said check your basket.
Thanks for the info, Andy B is right on the money , the basket is notched and it ain't cheap. Since this is the third time apart I hope its like the saying and third times a charm. :yahoo:
Quote from: vaquero45 on May 14, 2011, 10:10:39 AM
hello all, rebuilt the clutch on my 89 fj and am having a problem with it releasing when I pull in the clutch lever. This only happens when it sits for a day. I replaced the fiber discs and plates, the diaphragm spring and clutch boss,rebuilt the master and release cylinder.I have also checked push rod travel with the clutch cover removed and it seems good. What happens is when I roll her out for the day I have too warm her up good then shut her down put it in gear and rock the bike back and forth with the lever pulled in till the plates release. Is this just because everything is new and will free up as it breaks in. :ireful:
Normal, mine does it with all stock parts in the clutch...... also, it isn't good to warm her up before riding, 30 seconds or so is the most she should sit and idle. I rock her to break the plates loose, then fire her up and ride slow for a few miles..... 15-20 minutes and it's time for Kookaloo! :biggrin: