85 200x clutch issue

[Legns]

I HAVE BEEN REBUILDING A 200X FOR SOME TIME NOW. I HAVE THE MACHINE RUNNING NOW BUT EVERYTIME I GO TO PUT IT IN GEAR IT LUNGES FORWARD AND DIES AND YES I HAVE THE CLUTCH PULLED IN. I HAVE TAKEN THE CLUTCH COVER OFF TAKEN THE CLUCH BASKET OFF AND CHECKED ALL TOLLORANCES. THEY ARE GOOD. PUT IT ALL BACK TOGETHER FOLLOWED THE BOOK INSTRUTIONS TO A T AND ADJUSTED THE CABLE AS PER THE MANUAL. IT STILL WILL NOT DISENGAUGE. AM I MISSING SOMTHING? IT DOSE SHIFT INTO ALL GEARS WITH THE MOTOR OFF UP AND DOWN SO I DONT THINK ITS SOMTHING WITH THE TRANNY. I AM KINDOF AT A LOSS OF WHAT TO DO NEXT :wondering ANY HELP IS GREATLY APRICIATED THANKS

[oldskool83]

get a manual and make sure the actuator pin the controls the clutch was installed correctly.

[shortline10]

Does the inner clutch hub spin freely when you had all the clutch plates out ?
Also if you installed Heavy duty clutch springs they will have a tendency to make the clutch stick when the motor is cold .
I would just ride it for a while and see if it frees up .

[Dirtcrasher]

When the mainshaft nut is TIGHT, the outer basket must spin free of the inner basket. Otherwise, separating plates does nothing, hence the reason you don't need to install plates to troubleshoot this particular issue...

Just leave the plates out, assemble the inner basket on the mainshaft and tighten the nut. If it does not spin free, you have to back off the main shaft nut 1 flat of the nut, and or change the thrust washer in there to achieve that play/free movement that it must have...

[Legns]

So your saying to pretty much put the clutch basket back together minus the clutch plates and if the inner basket does not move freely from the outer basket there is a problem

[shortline10]

Correct the inner and outer baskets should spin free from each other .


So your saying to pretty much put the clutch basket back together minus the clutch plates and if the inner basket does not move freely from the outer basket there is a problem

[Dirtcrasher]

Mike said it first, I just elaborated :D

[Legns]

Sorry for the long response I have been working a lot lately. So I finally got a chance to do what was said. I put the Clutch basket together with out the clutch plates and it does not spin freely like it should. Now it does spin with a little bit of force from a small pry bar. I believe this is my problem. So far I have put everything back together gotten the motor up to operating temperatures and let it run for an hour or so at operating temperature. Then I rode it by going down a hill then putting it in gear. All the time holding the clutch in and shifting in and out of neutral as I rode it still won’t disengage. I think my only option now is to tear the whole motor down again and see if maybe I put an extra shim in somewhere or washer that’s the only thing I can think of at this point.

[Dirtcrasher]

You simply back the nut off one flat to allow them to be free.

Or, change one thrust washer, I swear I see this problem more than anyone else...

[Legns]

Ok I am not sure which nut you a referencing. I’ve added a picture to help explain what’s going on in my situation. I believe the larger shaft should be spinning freely and easily from the smaller shaft and it is not this is why I believe there something wrong inside the motor somewhere else. The shafts do move separate from each other but are very stiff.