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Issue with Clutch after replacing stator - messed it up

1591 Views 12 Replies 6 Participants Last post by  doug.enders
Need some help. My son and I just replaced the stator on his 2008 V-Strom 650 and while doing so the clutch assembly fell off completely. We put it back together, but now the clutch won't change the gears when the engine is running. Moreover, when I start it in first gear, the rear wheel moves me forward even when I have the clutch fully depressed at the handle. Note: We did not know to depress the clutch handle before removing the stator - didn't realize the clutch would be affected, and the clutch handle was depressed a few times while we were trying to figure out the problem - so the issue could lie there. Would appreciate some help if anyone knows how to fix. My son just bought this bike, doesn't have a lot of money and he is pretty sad at the moment.
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When you start the engine in first gear, or when you put the engine in first gear, it's normal for the rear wheel to move if the wheel is unloaded (off the ground, bike on the centerstand). The bike has a wet clutch and it requires a bit of force to break the stickiness of the oil on the clutch friction plates. The momentum and air resistance of a dangling rear wheel is not enough for that. BUT it should be extremely easy to stop the rear wheel from spinning by applying the tiniest bit of pressure on the rear brake pedal. So that part of your story is entirely normal.

I've never done a 650 clutch so I can't help you any further. But do you have a maintenance manual and did you follow that? Did you take a good look at a parts diagram and place everything back the way it should?

The 650 clutch is mechanical, while the 1000 clutch is hydraulic. So if you start reading about the procedure on the internet, make sure you read the right instructions. When you say "We did not know to depress the clutch handle before removing the stator" I think you were looking at instructions from a 1000, where this is important to avoid spilling hydro fluid. But probably not required - and possibly even detrimental - on a 650. In any case, do NOT keep the lever tied to the handlebar when reassembling the clutch slave: This leads to working under spring tension and crooked installations.
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When you start the engine in first gear, or when you put the engine in first gear, it's normal for the rear wheel to move if the wheel is unloaded (off the ground, bike on the centerstand). The bike has a wet clutch and it requires a bit of force to break the stickiness of the oil on the clutch friction plates. The momentum and air resistance of a dangling rear wheel is not enough for that. BUT it should be extremely easy to stop the rear wheel from spinning by applying the tiniest bit of pressure on the rear brake pedal. So that part of your story is entirely normal.

I've never done a 650 clutch so I can't help you any further. But do you have a maintenance manual and did you follow that? Did you take a good look at a parts diagram and place everything back the way it should?

The 650 clutch is mechanical, while the 1000 clutch is hydraulic. So if you start reading about the procedure on the internet, make sure you read the right instructions. When you say "We did not know to depress the clutch handle before removing the stator" I think you were looking at instructions from a 1000, where this is important to avoid spilling hydro fluid. But probably not required - and possibly even detrimental - on a 650. In any case, do NOT keep the lever tied to the handlebar when reassembling the clutch slave: This leads to working under spring tension and crooked installations.
Thank you. Appreciate the clarification re 1000 vs 650 clutch design.

The rear wheel is pushing the bike forward when I'm sitting on it, so under pressure.
Also, the maintenance manual only shows the basics of clutch adjustment. It wasn't helpful.
What happens when you apply the rear brake? A little bit of lurch in that situation is normal, but it should be easy to contain that with the rear brake. But if it's hard to contain, or if the engine stalls, well, that's indeed not normal.

Can you post a pic of the clutch assembly and in particular of the position of the adjustment things, both on the lever and on the engine end? And then both with the lever loose and pulled against the handlebar. Someone with more 650 experience can maybe tell you what's wrong from there.

Oh, and removal/reassembly of the clutch is probably further down in the manual. The way the manual is organised is somewhat by likelihood of the requirement of the procedure. Adjusting the clutch is common, so it's at the front. But removal/reassembly of the clutch is less likely so further down, probably deep into the "engine" section.
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Thank you. I will look there. Here are some photos of the clutch both at rest and withe the clutch lever pressed down; as well as a pic of the clutch lever itself.

I have a video but not sure how to post.
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Just be careful if you remove it disassemble to lube the 650 clutch actuation mechanism. It's got several small ball bearings. Took me 4 hours searching the garage floor to find them all 😳
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I'm pretty sure I got it figured out. I had to adjust the jam nut. Thanks!!
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I'm pretty sure I got it figured out. I had to adjust the jam nut. Thanks!!
When you adjust the lower jam nut, be sure there is still slack in the cable at the lever adjuster. After the lower adjustment is made do the lever adjuster.
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When you adjust the lower jam nut, be sure there is still slack in the cable at the lever adjuster. After the lower adjustment is made do the lever adjuster.
There is some slack. I tightened until I felt some resistance and then backed it out a bit. Thank you.
Glad you got it sorted out. Nobody wants the new motorcycle to have problems that were not anticipated.

And welcome to the club. It's a good group of folks and plenty knowledgeable.
Glad you got it sorted out. Nobody wants the new motorcycle to have problems that were not anticipated.

And welcome to the club. It's a good group of folks and plenty knowledgeable.
Thank you. My boy is very relieved. Replacing the stator was definitely a more demanding project than we had anticipated.
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