Zook / Suzuki DS80 1990 Clutch

[Bigfellaa]

Hey Guys,

i bought this DS80 for my young bloke but he had trouble finding the gears.
i haven't had much to do with bikes mechanically but thought i'd have a go.
i bought a service manual which has given me all the spring and plate specs and
everything ok but theres nothing about ressembling the clutch and clutch bolt tensions.
i haven't found much on the net other than tighten till firm.
i've tightened till firm and replaced clutch cover then dropped in clutch release rod? but the rod doesn't spring back when turned, i'm thinking because the clutch bolts are too tight and the springs cannot spring?? if that makes any sense.

 

[my67xr]

Welcome to Miniriders.

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Does the clutch release pinion rod mesh with the teeth on the clutch release rack/pusher ?
I cant remember off hand whether the gear on the clutch rack face's forward or backward's.

Have you hooked up the clutch cable and adjusted it so there is only a couple of mm slack at the clutch lever on the bar's.?
You wont be able to move the clutch arm on the clutch cover just with your hand.

 

[Bigfellaa]

Thanks for the reply My67xr.
The release bolt sticks out of the basket and the the pusher rod ( the rod that the clutch cable attaches to) are meshing.
I think it's got something to do with the tension on the clutch spring.
Before I pulled apart, I could turn the pusher using vice grips and it would spring back, this is not happening now as I'm thinking the clutch spring bolts are to tight.
I was thinking about just nipping them up but they don't seem real tight, maybe the springs will hold the tension and stop them from coming loose?.

 

[my67xr]

Did you have any luck sorting your clutch ?