clutch problem after replacing front sprocket

[rjb/AKA Bob Barram]

I replaced the front sprocket which requires removing the panel that holds the clutch relay between the cable and the clutch. I put it back on and there is no pressure from the clutch. I have had this piece off about 3 times in the past and never had this problem. Is it possible the push rod is bad or came loose? Any ideas appreciated.

[hootmon]

I Assume this is not Gen 3...

[TLRam1]

Check to see if you have the cover seated properly or the pivotal lever to push the clutch rod is not pushed down into the cover properly (I'm talking the lever you put your clutch cable into).

[rjb/AKA Bob Barram]

It is 3rd Gen. I was sure of the cover position, I was able to put in all three screw tightly. The clutch lever does not return when released. The push rod that goes into the clutch assembly will slide all the way out now, never have seen that before.

[TLRam1]

IIRC the push rod will come out with little effort. There may be a spacer the clutch lever pushes on that hits the push rod. If you look in your cover and move the lever you will see the spacer that moves. You have to apply pressure my means of a object to push the spacer back into the cover.

I will say this in an easier fashion. If you apply pressure with an object where the clutch rod would go and move the lever the spacer will go up and down with the movements of the lever. I don't know if spacer can fall out of the cover but on other bikes it can. 

[TLRam1]

Also if the clutch rod comes out some bikes have a ball bearing as a spacer also that can get lost, I would have to look at a diagram and see if the Magna has one.

[TLRam1]

I didn't see a ball bearing so if the above works you should be good to go.

[rjb/AKA Bob Barram]

Thanks,Terry, went through those options last night during my two hours of trouble.
That is what has me confused, it is like the clutch lever is not  hitting the push rod at all, preventing the spring back that should happen when you release.
I have pushed the rod back in but it is like it is not going in the last 1/16 inch that it should. I can tell this by the clean part of the rod before the end that did not go into the clutch casing.

[TLRam1]

I am racking my brain and can't think what it could be Bob. I am sure you jiggled the rod around trying to get it seated. Can you pull the rod out and see what's possibly holding it up looking thru the hole with a light?

If I understand you properly, the clutch push rod will not go all the way into the engine case and seat on the pressure plate of the clutch, correct? Last resort if someone doesn't come up with other ideas or a solution would be take off the case cover on the clutch side and remove the pressure plate to see what's in the way. 

You would need a case cover gasket if you do this or use Yamabond or equal to reseal.

[rjb/AKA Bob Barram]

Thanks for sufffering with me. When I do pull the rod out oil starts leaking out so I never went any further in that direction last night. May try that today.
Thanks again.

[hootmon]

Silly question and I do understand it was not part of the original problem, but can the rod be put in backwards and does it make a difference???

[Greg Cothern]

I just had this issue with my Project 96, I pushed the pin into the cover with the cover in my hands, worked the lever (the part the cable connects too) and rotated it with gentle pressure against the pin and in slid into place.  I then slid the cover into place.

[dgc67]

I heard a rumor that do to this problem, Bob has been given permission to buy a new bike!

[rjb/AKA Bob Barram]

As far as the rod goes, it goes in too far, thus not putting any pressure on the clutch linkage that goes to the handle bar lever.
I am sure it is not backwards, but to that point both ends are the same with some tooling on the rod off center.
I had Jeff help me get it to Maxim Honda dealer on a trailer. (oh man, that's hard to say-trailer!!!)
They may get to it Tuesday. (that hurts even more)

As to DG's comments, we do not want to go there yet, I would hate to scare away those Valk riders with a faster stead.....LOL

[TLRam1]

Wonder if your lever is broke inside the cover or some sort? Curious to hear what this is Bob.