Ace 100 Clutch problems

[archdukeferdinand]

Hi. I recently acquired a 1967 ace 100cc. I've gone through the engine and replaced all the bearings and seal. I put the engine back in the bike, and it all worked fine, compression, shifting, everything. However, when i put oil in the transmission, the clutch stopped fully disengaging. i checked the cable and its taught, and the clutch has loosened up a but since this started happening. i have just been rolling it and putting it into gear to test this because in need some carb gaskets before it can run. Is this normal or did i mess something up. Im only 16 and this is my first Hodaka, so any advice would be greatly appreciated.

-Thanks!

[dirty_rat]

Too hard to tell just from what you have written. Is there any slack in the clutch cable? What type and amount of oil did you use? Did you get the clutch actuating bearing (roller bearing that fits into hole on clutch outer cover and presses on clutch disk) inserted properly? Is the clutch nut (only left handed nut on the bike) tightened properly? Is the clutch bushing the proper length (not worn out) and mounted properly? Check these things and let us know and we can go from there.

[archdukeferdinand]

No there is no slack, i used basic 30 weight oil and filled it a little above the line on the dipstick, i'm pretty sure i got the bearing in correctly. the nut is tightened, but i didn't have the lock washer so i bought a basic internal lack washer from the hardware store and it was a little large and had some wiggle room. i centered it best i could . i know thats a little unprofessional haha. Also there are all brand new clutch plates. What are areas that typically have issues that i could check. or is it possible that it will just find its place and loosen up over time.

[Bullfrog]

Let's have you check the freeplay of the clutch lever at the engine.

- Remove the cable from the end of the lever (the lever at the engine). You can use a large screw driver resting on the side cover screw boss to pry the lever up and move the cable end out of the slot in the end of the clutch lever.
- With the cable disconnected . . . measure how much freeplay there is at the end of the clutch lever on the engine
- Let us know what you find

Ed

[dirty_rat]

The lockwasher could be the problem. It is probably much thicker than the original lockwasher and could therefore be interfering with the clutch disk. Try to take the lockwasher out and put it together without any washer. Try it without running the bike, If the trouble goes away, that was the problem and order a new lockwasher from Strictly Hodaka before running the bike.

[Zyx]

Probably just oil drag. Wet clutches feel as if they do not fully release especially when the engine isn't running. This I'd not like the clutch on a car. Full release isn't the same as freewheel. They release only marginally. Try pulling the clutch lever and tying the lever down overnight. Let the discs sit in oil without spring pressure, try again after that. But really this is a matter of degree and is subjective without a frame of reference. For example, how are you determining that that it isn't fully released? Did you by chance run the engine without transmission oil and if so, did you pull the clutch? If you ran without oil with the clutch pulled, it would be quite easy to seize the pinion bushing.

Describe what you did before the oil when it felt free and then what you did after adding oil.

[ossa95d]

At this point I think we are all overthinking this. The bike does not run yet so what the owner is experiencing is clutch drag when trying to push the bike in gear with the engine not running. This is normal with a wet clutch especially with the clutch on the end of the crankshaft. I suspect everything is fine. The owner should check freeplay of the lever at the engine as Ed has suggested though.

[archdukeferdinand]

Thanks everyone. i will try all those things, but also i agree with the previous post that it might just be that the plates aren't worn in and i just need to run the bike before i worry too much. I will get the right washer and ask later if the problem persists. thanks!