New clutch installed but clutch is backwards??

[B-Rad]

heyy guys
So im not that good with mechanics and i have just installed a new clutch unit in my 155z. the problem is that when i dont pull in the clutch lever the clutch is engaged and when i pull in the lever the clutch is disengaged so i can change into 1st without doing anything and when i want to go i would have to pull in the clutch????
How can i fix this backwards issue
Cheers

 

[sean01]

hmmm sounds pretty weird to me..

check that you installed the 2 washers correctly... fat one first then turn it in the shaft then slide the thin over the fat one to lock it in position

 

[The_GDFP]

Maybe the inner and outer baskets aren't splined together? Regardless, it's gonna take cover removal. A pic or two may help.

 

[B-Rad]

well i have a few parts spare.... i have a big tube thing thats like 4cm long and a washer thing with all the things spiking up??? i installed it how the old one was?? ill have a look in a few days when i have some time

 

[B-Rad]

does anyone have an expanded diagram of how to do it???

 

[sean01]

if you have parts spare then you clearly haven't installed how the old one was

 

[sean01]

how about you post a pic of the parts left over.. i'v already mentioned where that washer goes but not sure on the other part you mentioned

 

[B-Rad]

ok i will pull it all apart in the next few days and have another look does anyone have diagram??

 

[sean01]

i recon there might be one in my sig

 

[B-Rad]

yer but the one for 155z doesnt work??????

 

[motodevo]

page 5
http://www.dhz.com.au/assets/brochures/EN-09.pdf

 

[sean01]

yep just fixed the links

 

[B-Rad]

Well i instaled it according to the diagram and it still doesnt work it cant find a gear and when it does the clutch still acts backwards help

 

[westy465]

page 4 number 11


http://www.dhz.com.au/assets/brochures/EN-09.pdf

if I rember correctly, and I i have been wrong in the past, this shaft has a keyway in it that matches up with the pin that engages the clutch. theres no way you could have put that in backwards? thats the only way I can think of the clutch operating in reverse.

otherwise just get a cable tie and lock your lever on.

 

[B-Rad]

Yes ive already looked at that and i cant find anyway u could put it backwards
Help please

 

[sean01]

ok so your absolutely sure the 2 washers are in correctly? next step is to back the 4 clutch spring bolts off till there is no tension then try and wriggle it all and see if it pops out a little. if so then do them back up evenly and try again...

but i think its time you recorded a short video of you installing the clutch from the start..

 

[B-Rad]

Well theres the big washer with grooves to fit on the shaft and then theres the one with 3 spike stickin out?? The one with the spikes makes it very hard to get on and it takes a long time to wiggle and jiggle it on. But when i do het it on the last cover thing u put on the clutch it sticks out a bit but without that spiky wasker it can go on easly ang push in further without stickin out?? I have already snapped one washer with spikes try to get it in further when its all tight should the discs be able to move??

 

[sean01]

yep, your installing the washers wrong.. its an easy task and only should take 2 blinks..

slide the fat washer over the shaft and turn it in the groove on the shaft, then slide the thin spikey washer over the shaft so the spikes go thru the fat washer which locks them in place..

and no the clutch plates should be all firm and you shouldnt be able to move them

 

[sean01]

try this.. from about 5mins forward

<iframe width="420" height="345" src="http://www.youtube.com/embed/Q9v2tz1tuAg" frameborder="0" allowfullscreen></iframe>

 

[B-Rad]

Ok thanks for that sean now it is corectly installed as you said but the clutch isnt working at all i select a gear without clutch and it goes into gear and the bak wheel locks up( cause im testing it while its off ) and it does the same with clutch in the clutch is installed right but it just isnt working, i loosened the springs off but it didnt pop out also how tight should i do the spring up???