2004 RM85 Clutch Issues. Need quick Response please!!

O

owenj199914

Hey guys,
I just now finally got to putting my 2004 RM85 back together. I had taken the crank case off to replace the water pump, bearings, oil seals, etc. I put the case back on and while putting it back together I heard a lot of popping noises, and the clutch will not open. So I took the case back apart and noticed 1 tooth missing from the clutch lever gear. I was wondering if this was meant to be like this to allow for the case to be taken off or if the lever gear is broken.

Thanks for the help,
Owen
 
O

owenj199914

Not now I don't. I just closed the case with gasket glue about 2 hours ago but I am planning on replacing the part and gasket again. I will try and take it apart tomorrow and upload a pic if possible.
 
SRAD97750

SRAD97750

Moderator
Staff member
Sometimes things are tricky when installing a clutch cover without any binding.
When I hear noises, or it's not going smoothly, i'll take it back apart and try again.
Was the clutch properly adjusted before you removed the cover?
What do you mean by, "the clutch will not open?"
 
O

owenj199914

When I had taken the cover off, it made a bunch of cracking/popping noises, so I figured it was fine.

The clutch was adjusted correctly and worked 100% before I took the cover off....

The clutch plates will not open when you pull the dog leg lever. The plate that opens when you pull the handle only moves a tiny bit which is the play in the cable. The teeth in the mechanism the cable attaches to has a tooth missing that I don't believe was missing before I took it apart and I think that's what was making the popping noise during reassembly.
 
2strokesteve89

2strokesteve89

look around your work area and inside behind the crankcase cover when you get it back off for the piece that broke (if it did break), that will tell ya for sure there is a problem. that being said, popping/or crunching noises is never good to hear when putting case halves or crank covers together. let me know what you find.
 
O

owenj199914

ok! I will try and take it apart tomorrow sometime during the day. I am planning on buying the parts that need replacement. Do you know any sites or should I buy this from babbots wear house? They were reliable, but a bit pricy and slow shipping for the price.
 
O

owenj199914

That's always good everywhere lol! And I will give them a look tomorrow. I will keep you posted with pics if I am able to take the cover off tomorrow.
 
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