Clutch won't catch

I took my clutch cover off to clean the inside and give the plates a good cleaning and now I don't know how to get the cover back on without the clutch lever having way too much play in it.

I've adjusted all the adjustment pieces and nothing, but I have noticed that the spring assembly coming out of the clutch is at a higher angle than it was before. Through my best efforts I cannot get it to set correctly.

Any ideas?

 

Take the throwout lever OFF. Be sure the "pushrod" (the bit with the gear teeth on it that catches on the teeth on the actuator shaft) is properly positioned and install the cover.

Once the cover is on/bolts tight, rotate the shaft CLOCKWISE when viewed from above <edit> "above" being in relation to the actuator shaft, I just remembered yours is on an angle> until it stops. Install the spring, washer and lever, with the lever lined up with the mark on the cover. If this position doesn't give you enough "actuation" throw, you can back the lever up (CCW on the shaft) one set of splines.

When the shaft rotates counterclockwise, it pulls on the wrongly-named "pushrod" and lifts the pressure plate off the discs. It has to be pulled up to make contact (the slack taken out) before you install the lever.

Trying to reinstall the cover with the lever on the shaft is a crapshoot as far as getting it in the right position. MUCH easier to just take the lever off.

 

Actually, my mistake. I didn't have the pressure plate properly seated. It was slightly off and that was making my clutch lever soft. :lol: