Transmission issue

[Mittzy]

Installed engine and assembled bike over the week but when was ready to start & test engine have couple of issues.

>The clutch plates doesn't seem dis-engage even though lifter piece appears to pulling the clutch pressure plate.The linkage appears to be pulling the lifter piece as the tension is higher than the return spring of linkage by itself.Could this be adjustment issue of the cable?

>Odyssey PC625 is around 3 years old was stored inside home and charged couple of times since motorcycle was down over the year.It has only 12VDC charge even after charging overnight.Tried starting with jump starting from my car battery(runnin) ,measured 14VDC but made a mistake .I had forgot to put gear in neutral and heard grinding noise from starter momentarily (no burnt smell or fuse wasn't blown either).The engine didnt turn over during this crank cycle

Now if i try to start engine without jump startimg, can hear the start relay click and also solenoid on starter click but starter won't crank over.Is there a minium voltage for starter to turn over or could the starter motor may have got damaged


I am looking at buying a new battery and starting tomorrow.

If you don't have enough battery power the solenoid may engage but wont turn the motor over - should not be any issues in jump starting from the car though.

 

[warp9.9]

Do you have a stock clutch system ? If so did you make sure you installed the correct rear clutch fiber ? The rear one has a larger inside diameter so it will clear the anti-judder spring and seat. If you mixed this it will probably make the clutch act up. Another thing I have seen is not slowly and evenly taking up the bolts on the pressure plate and clutch springs like bolting a wheel on your car, and warping the plates which makes the clutch grabby.

 

[v*twin]

If you don't have enough battery power the solenoid may engage but wont turn the motor over - should not be any issues in jump starting from the car though.

The clutch system has all stock components and made sure I installed the plates back same orientation as I had taken them out.The plates were oiled and springs torqued to 10nm .
After installation of pressure plate had checked lifter piece action but I couldn't move the pressure plate back.I had assumed the plates will losen up after rotation and did't want to damage the lifeter piece button.

Is it typically possible to varify clutch action by pulling lifter piece before bolting on tbe clutch engine cover.

I was planning to change engine oil & fiter after few mintues of running engine .Also had ordered a spare clutch cover gasket just in case,looks like will end up using it now.

Do you have a stock clutch system ? If so did you make sure you got the right rear clutch fiber installed? the rear one has a larger inside diameter so it will clear the anti-judder spring and seat. if you got this mixed up it will probably make the clutch act up. Another thing I have seen is not slowly and evenly taking up the bolts on the pressure plate and clutch springs like bolting a wheel on your car. and warping the plates which makes the clutch grabby.

 

[warp9.9]

The clutch system has all stock components and made sure I installed the plates back same orientation as I had taken them out.The plates were oiled and springs torqued to 10nm .
After installation of pressure plate had checked lifter piece action but I couldn't move the pressure plate back.I had assumed the plates will losen up after rotation and did't want to damage the lifeter piece button.

Is it typically possible to varify clutch action by pulling lifter piece before bolting on tbe clutch engine cover.

I was planning to change engine oil & fiter after few mintues of running engine .Also had ordered a spare clutch cover gasket just in case,looks like will end up using it now.

Before you take her apart let's check things. I know on early Rockets some did not have any alignment markings on the lifter shaft arm or the shaft so I am curious as to where yours is located? This is important for shaft rotation. Also what does your free play feel like or can you say for sure there is some.
Pictured below are the alignment markings to which I was referring.

 

[v*twin]

before you take her apart lets check things. I know early Rockets some did not have any alignment markings on the lifter shaft arm or the shaft so I am curious as to where yours is located? This is important for shaft rotation. also what does your free play feel like or can you say for sure there is some.
pictured be low is the alignment markings I was referring to.

There is no marking on the lifter shaft arm but there is the dot mark on the shaft. Currently the shaft arm is at the same position as in the photo aligned with shaft marking.

I had some luck, was about to pull battery out to get a new replacement battery and decided to jump start one last time. There is some gremlins in the harness or gear position sensor ,had to pull hard on the Gear position sensor wire into a position for Neutral indication light & Oil pressure light on the gauge to light up after which engine started up.

Operated engine momentarily and will run longer in the evening and check the error code, it seemed to run a little rough and there was an error code on the gauge .

 

[v*twin]

The only thing I was not sure of is the orientation of Clutch basket bearing sleeve, I had it installed with the 4 cross slots facing towards clutch pressure plate

before you take her apart lets check things. I know early Rockets some did not have any alignment markings on the lifter shaft arm or the shaft so I am curious as to where yours is located? This is important for shaft rotation. also what does your free play feel like or can you say for sure there is some.
pictured be low is the alignment markings I was referring to.

 

[warp9.9]

The only thing I was not sure of is the orientation of Clutch basket bearing sleeve, I had it installed with the 4 cross slots facing towards clutch pressure plate

Correct

I can see you did not do the full update as it has the old detent wheel

 

[v*twin]

The only thing I was not sure of is the orientation of Clutch basket bearing sleeve, I had it installed with the 4 cross slots facing towards clutch pressure plate

before you take her apart lets check things. I know early Rockets some did not have any alignment markings on the lifter shaft arm or the shaft so I am curious as to where yours is located? This is important for shaft rotation. also what does your free play feel like or can you say for sure there is some.
pictured be low is the alignment markings I was referring to.

Correct

I can see you did not do the full update as it has the old detent wheel

Yeah, only parts changed on transmission were the output shaft gear and output damper but left all clutch and gear selector mechanism as it is.(changed the judder spring and all washers in clutch assembly)

 

[Paul Bryant]

Correct

I can see you did not do the full update as it has the old detent wheel

Can you show me a photo of the later one Scot please ?

 

[Rocket Scientist]

Correct

I can see you did not do the full update as it has the old detent wheel

One of the old ones, with the good spring