Slipper clutch retrofit into 2015 FJ09, now I can’t shift into 1st without stalling

[EJD87]

I’m at wits’ end. I have no idea what to do. The new clutch plate stack is within spec. We’ve installed EVERYTHING correctly. Although I’m using the original part number clutch cable (the one with the weird bend that frays the cable over time), this shouldn’t affect the bike’s ability to disengage the clutch with the lever in, especially since it’s been adjusted to be as tight as possible, and I had no issue with it previously. 

I think it might be something having to do with the push lever assembly that engages with the push rod. It seems to “lock” instead of bringing the push rod and clutch plates out away from the engine. We can’t feel that spring tension. What could possibly be happening here?

[EJD87]

12 minutes ago, EJD87 said:

I’m at wits’ end. I have no idea what to do. The new clutch plate stack is within spec. We’ve installed EVERYTHING correctly. Although I’m using the original part number clutch cable (the one with the weird bend that frays the cable over time), this shouldn’t affect the bike’s ability to disengage the clutch with the lever in, especially since it’s been adjusted to be as tight as possible, and I had no issue with it previously. 

I think it might be something having to do with the push lever assembly that engages with the push rod. It seems to “lock” instead of bringing the push rod and clutch plates out away from the engine. We can’t feel that spring tension. What could possibly be happening here?

To clarify, it seems I’m unable to unload the transmission at all after putting in this god-forsaken “upgrade,” rendering the bike unusable. 

[2and3cylinders]

I'll bite

I installed one in my fastest red 15 years ago and it's worked great since 

So to go out on limb

You did something wrong  😎

[EJD87]

9 minutes ago, 2and3cylinders said:

I'll bite

I installed one in my fastest red 15 years ago and it's worked great since 

So to go out on limb

You did something wrong  😎

Wow, what a profoundly useful comment. 

[dazzler24]

8 hours ago, EJD87 said:

I think it might be something having to do with the push lever assembly that engages with the push rod. It seems to “lock” instead of bringing the push rod and clutch plates out away from the engine. We can’t feel that spring tension. What could possibly be happening here?

That was my first thought on reading this.  I'll find the technique I used when reinstalling the clutch cover to ensure that the push rod engaged correctly with the lever.  I'll be back.......

OK here is my post on how I aligned things to get a working clutch.

HTHs

EDIT: - there's other advice tips in that thread from the learned community that may/should help as well.  Good luck.

[2and3cylinders]

5 hours ago, EJD87 said:

Wow, what a profoundly useful comment. 

 

I'm always here to lend a hand.

Another suggestion 

Start over...

[bwringer]

10 hours ago, dazzler24 said:

That was my first thought on reading this.  I'll find the technique I used when reinstalling the clutch cover to ensure that the push rod engaged correctly with the lever.  I'll be back.......

OK here is my post on how I aligned things to get a working clutch.

HTHs

EDIT: - there's other advice tips in that thread from the learned community that may/should help as well.  Good luck.

Yep, it took me three tries to get this right too. I think your answer lies somewhere in there. You have to get the arm clocked just right, while juggling the tension of the spring on the cable, etc.

No shame in it, and FWIW, the gasket will be just fine during multiple on/off cycles.

 

Where y'at? Maybe there's someone nearby who's bored and been through this.

Edited May 13, 2023 by bwringer