atc 125m moves at low idle (auto clutch??)

[sammiefish]

my 125m automatic clutch (or something) wont stop moving even at low idle. It acts like the auto clutch stays engaged. exactly backwards of what Id expect a worn clutch to do.
I just replaced the case half to fix a broken shift stop boss and also replaced the dry clutch disks. any idea why the automatic clutch wont disengage. If I got the external clutch assembled improperly would that do this. I can ride it but the shifter now acts like a real clutch... only way bike wont move is in neutral..... hmmm... i did replace the oil with regular oil (not ATV) but this never did this before...
any ideas?

thanks,
Chris

[BarnBoy]

Chris,

I put a new clutch in my 200M about a year ago. New shoes and friction plates. I havent been able to ride it much since then at all, so it does pull at idle. I think it just needs to be ridden a bit for stuff to wear in. I know it is adjusted right.

With yours, I would check the clutch adjustment. I do not believe that you assembling the friction plates wrong would cause this problem, but it is possible. Maybe if you didnt torque stuff down properly, or didnt stack the clutch plates properly? It may just need to wear in some, but if you are grinding gears at all I wouldnt ride it. I would definitely run only ATV oil that is meant for use on wet clutches. It will say on the can.

Let us know if that works.

[Blown 331]

I think I may know what your problem is. I just ran into this on an ATC110 I just picked up. I searched high and low for an answer with no luck and finally had to dig into it. Did you happen to put your steel clutch plates back in the order displayed from a parts diagram like the one in this link? If so the parts diagram is wrong. Number 8 and 9 are swapped. If you have an actual repair manual they are shown in the correct order, at least mine is. So someone was obviously in my bike before I bought it and put it back together according to a parts diagram which is wrong. My clutch would work correctly if I put about two turns of preload on the clutch adjustment rather than having free play. I knew that wasn't worth a crap so that's when I took it apart.
http://www.bikebandit.com/oem-parts/.../m1875sch10666

[sammiefish]

Chris,

I put a new clutch in my 200M about a year ago. New shoes and friction plates. I havent been able to ride it much since then at all, so it does pull at idle. I think it just needs to be ridden a bit for stuff to wear in. I know it is adjusted right.

With yours, I would check the clutch adjustment. I do not believe that you assembling the friction plates wrong would cause this problem, but it is possible. Maybe if you didnt torque stuff down properly, or didnt stack the clutch plates properly? It may just need to wear in some, but if you are grinding gears at all I wouldnt ride it. I would definitely run only ATV oil that is meant for use on wet clutches. It will say on the can.

Let us know if that works.

Thanks for the reply. Its possible but i think i just reassembled in reverse of taking apart but i dont remember for sure... I can try the ATV oil with the friction modifiers... maybe the weight spring broke or is hung up?? hmmm

[sammiefish]

thanks for the idea... I do have a manual so I can check...

I think I may know what your problem is. I just ran into this on an ATC110 I just picked up. I searched high and low for an answer with no luck and finally had to dig into it. Did you happen to put your steel clutch plates back in the order displayed from a parts diagram like the one in this link? If so the parts diagram is wrong. Number 8 and 9 are swapped. If you have an actual repair manual they are shown in the correct order, at least mine is. So someone was obviously in my bike before I bought it and put it back together according to a parts diagram which is wrong. My clutch would work correctly if I put about two turns of preload on the clutch adjustment rather than having free play. I knew that wasn't worth a crap so that's when I took it apart.
http://www.bikebandit.com/oem-parts/.../m1875sch10666