Vehicles

650 - getting it running part 3: clutch

As I reassembled the engine I kept trying to turn over the engine. This way if it siezed, I only had to go back one step to figure out what broke it.

Well, all was good until I fitted my clutch and torqued it down to 50 ft lbs. Once I did that, I could not get anything to turn over. Prior to that, the crank turned over and so did the tranny, albeit independantly.

I read and reread my manual on the clutch and tried all possible permutaions of washers and spacers.No matter what I did, once the clutch hub was installed and torqued down, the egine would no longer turn over.

After much thinking, searching, and plenty of help form some buddies on a forum, I determined that I was missing a washer. A simple washer was preventing my engine from turning over.

I ordered a replacement $2 washer and fitted it when it arrived. With the new washer in place, everything turned over exactly as it should have! Yah.

My problem was not really that I was missing a washer. It was that the washer I had in one spot was too big. This is the washer that sits against the tranny bearing. The larger washer sat on the outer race of the tranny bearing. The outer race does not spin. This washer ends up supporting the force of the clutch hub being torqued down. The washer was on part of the bearing that did not spin. The clutch hub was on the washer so when the clutch hub was tightened down, it didnt spin either.

The solution was to fit the correct, smaller outer diameter washer. This sits on the inner race of the tranny bearing. This part does spin. When the clutch hub is tightened down, it spins with the washer which spins with the inner race of the tranny bearing. Its hard to believe all this trouble was caused by a washer that was 15 mm to big on the O.D.

Its also hard to believe how crappy the clutch diagrams are in all my 650 workshop manuals. First, I swear they are drawn in crayon on a cocktail napkin. The lines are too thick to see any detail. Second, they are just plain wrong too. They dont actually show the washers used on an 81. I had to hit the internet forums to find a diagram that was actually correct for my year.

Pictures

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ordered two new washers, only the right one was absolutely required
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new washer sits on inner tranny bearing race, existing thick washer
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new washer in place
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existing thick washer in place
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space next
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next comes the clutch basket
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remaining washers fitted
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clutch hub fitted with lock washer, lock tab washer, and nut
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all done and ready for use. still spins like a champ
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bad bad evil washer shown in the back. too big O.D so it sits on bearing outer race
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missing the smaller washer I had to order, one larger I.D. washer was not needed
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