I just replaced my clutch cable, but now that I've put everything back together I have a problem. The bike will from neutral to first and back without the clutch lever pulled in. However it also won't go into second or any gear above. Did i miss something putting it back together? Are the clutch and the gears just not communicating? I appreciate any help?

The first thing you'll need to do is relax the tension in your clutch cable. Then adjust it n see if it works.your cable must be the problem.try taking it out and sork it in some oil n try freely moving it put back n see if it works

Sounds like when you put it together a shift fork didn't go back where it belongs. Try putting it together making sure it stays in neutral start to finish.

check clutch cable put back ok, is the cable adjusted so it goes completely loose when not being used. is the clutch pushrod under casing put back wrong or mechanism that clutch cable leads to under panel replaced wrong

did you adjust the clutch after you put it all together

the clutch may be stuck on. Put the bike in neutral, start the bike, run down the road looking like a fool jumping on and off the bike to kick it into 2nd gear and pumping clutch lever. Clutch should be free.

It might also be worth checking if your pushrod has a ball bearing in the end, I had one on mine, replace the clutch plates and it wouldn't work with the ball bearing in :)

How many miles are on it? You can try adjusting the clutch cable, there is a thumbwheel and adjuster bolt on the clutch lever perch where the cable goes into it. Simply loosen the thumbwheel, then turn the bolt outwards untill the excess cable slack is taken up. ONLY TAKE UP THE SLACK!! If this does not aleviate the problem, you likely have transmission problems- the slots and dogs in the transmission gears become worn with use/abuse- the most common ****** problem is clattering when putting into first gear, and difficult/missed 1-2 upshift. If your bike sometimes doesn't want to go into 2nd gear (requires double shifting, or seems to want to go into neutral before going into second) it's a sure sign of transmission wear. This can sometimes be repaired by replacing/ re-cutting and grinding the 1-2 gearsets, but in most cases it requires major disassembly of bottom end of the engine. This is a several hundred dollar repair, easy, and not one that many shops will be willing to take on with an older bike.

This could mean that you need to adjust the clutch or you may have too much oil in the primary chain case. First the easy thing to check. Take the derby cover off the primary and check the level of the oil with the bike standing straight up. With the side car, that should be no problem. The oil level should be just up to the bottom of the outer clutch drum. That's the bright aluminum "ring" around the clutch assembly. Too much oil and it gets between the clutch plates and acts like the transmission fluid in a torque converter in an automobile. Don't overfill your primary chaincase.

If you want to adjust the clutch, find the clutch cable adjuster, slide the rubber boot up or down to gain access to the adjuster. Loosen the lock nut and turn the adjuster barrel inwards to get a good bit of slack in the cable. At the derby cover, which should still be off, you'll see and adjuster in the center of the clutch assembly. Loosen the lock nut and turn the center adjuster screw inwards until you feel a resistance. Do not force the screw, just until you feel the resistance. If you need to, turn the screw back out and then in again until you get the feel of what you're doing. Once you've got the screw turned in until you feel the resistance, back the screw back out 1/2 turn and lock the locknut down. Put the derby cover back on. Go back to the cable adjuster and turn the adjuster barrel outwards until you've got about 1/8 inch of slack in the cable. Lock the lock nut down and replace the protective boot.

Good Luck
Steve

With the engine off, put the bike in gear and try to push it. If it rolls, your clutch is disengaged for some reason. You'll have to pull the end off of the transmission where the clutch cable goes in and check to find out what's wrong.

Good Luck
Steve

To replace the clutch discs in your clutch pack, first disconnect the battery and drain the oil from the primary case. Remove the primary case. Take the circlip in the middle of the clutch assembly out and remove the clutch adjuster plate. Then loosen and remove the bolts that hold the clutch together. Loosen them all and take them out evenly loosening each bolt one or two turns at a time so as not to warp the clutch spring. Once you get this off, you can remove the spring and the clutch plates. As you take the individual parts out, notice the sequence that they are installed in the clutch basket. When you replace the parts you wish to replace, make sure you get everything back in the proper order. Put a little Loctite 242 med. blue on each of the bolts that hold the spring plate on. Replace the clutch adjuster plate and circlip. Replace the primary cover and fill with oil up to the bottom edge of the outer clutch basket with the bike standing straight up. Do not overfill or your clutch will drag. Adjust the clutch according to the manual.

To adjust the clutch, find the clutch cable adjuster in the middle of the clutch cable. Slide the protective boot up or down and loosen the lock nut. Turn the adjuster barrel inwards to get as much slack as you can get.

Remove the derby if you don't have it off. Loosen the lock nut on the adjuster screw in the middle of the clutch assembly. Back the center screw up until it's completely free and then turn it back in until you feel a resistance. DO NOT FORCE THE SCREW. It will break the inner clutch hub if you force it. If necessary, perform this several times to get the "feel" of what you're doing. Once you feel the resistance, stop, then back off 1/2 turn. Tighten the lock nut down.

Then go back to the cable adjuster and turn the adjuster barrel out until you've got about an 1/8 freeplay in the cable. Squeeze the clutch a few times and recheck the freeplay. Tighten the lock nut and replace the rubber boot.

Good Luck
Steve

Hello,

Your clutch is maybe malfunctionning.
Check if your clutch cable is tight enough.