Chaly clutch issue

Hi guys,

Hopefully someone out there can help me, I love my bikes but my mechanic skills are not what they should be!

I'm struggling setting up the clutch, having done some reading up, the clutch should disengage if you apply light pressure to the gear lever when in gear. I cannot get to this point, despite adjusting the clutch according to the manual. Because of this the gear change is very clunky when engaging first even at low revs.

Has anyone out ther got any suggestions or tips please?

Many thanks
Chuffy

Did you dissamble any part of the clutch prior to this issue?

Hi Waynus,

Thanks for your response. No I have not dismantled any part of the clutch to date.

I have two Chaly's and the more recently purchased one, has the issue I described. Following a recent ride out, I also found the bike reluctant to go into 3rd gear. If I roll off the throttle a little and press the gear lever, it does not always want to engage. After a couples of prods it gets there but by this time the speed has dropped to the point where you should be back in 2nd !

Cheers
Chuffy

I guess it's about time you check the clutch plates and fork for wear...
That is, if the problem resists after setting the bolt correctly.

Thanks again Waynus,

You could well be right about the plates and forks, I was hoping to get away without removing the crankcase!

I am also a little confused about the adjustment. I have seen instructions on the web to turn clockwise until resistance is felt and back off 1/8 turn, but also turn counter clockwise and back off 1/8 turn. Obviously these contradict each other, which is correct in your opinion please?

Many thanks
Chuffy

Normally, tou'd want to back off so it becomes a bit loose. Otherwise, you might end up with a stiff gear lever.
Worth a try!

Have a look under the crankcase cover and see if any part of the mechanism has rough edges or has grooves worn in. You may be able to dress them down and get a smoother operation. If had to do this a few times with these engines over the years because many owners abuse them because to them it is merely a means of transport rather than a prized possession.

It will be a good chance to clean out the centrifugal oil filter too. These often get missed!