Well, I finally got my Big Red running nicely, but I went to put it in gear, and now it won't move. I can push it around easily with it in gear and the engine off, which I couldn't do before. I'm pretty sure it happened after I took the oil pump cup off and cleaned it. I put it all back together correctly, so I have no clue as to what the problem could be. Before I cleaned the pump cup, it drove great. Anyone have any ideas?

Thanks,
Tony C.

 

I would first adjust the clutch , which should be done anytime the clutch cover is off .. If the clutch adj is fine then are you sure you got the clutch cover back on without anything moving out of place like the ball retainer (the plate with the 3 ball rollers) or the lifter plate spring ..

Did you clean the centrifugal oil filter with the bike on it's wheels or rolled up sideways on 2 wheels..?

Here is the clutch adjustment..

 

Thanks for the reply. The clutch adjustment is tight, so I made it a little easier. I cleaned the filter with the bike on all 3 wheels. I was pretty sure that I got the cover on with everything in place, but now I'm not as sure (lol). I just hope I didn't ruin anything while I had the bike running for 20 - 25 min. Should I lay the bike down when I take the cover back off?

 

The clutch was wayyy out of adjustment, and it works great now. I really appreciate all the great tech and advice I've been given on this board. My Big Red would have been nothing without all your help. I still have a question though. When you first start off in gear, the clutch is real slippy, but then it grabs great and takes off. Is that normal? I think it is, because it is the same way with manual trans cars. It would ease my mind if I knew for sure.

Thanks a million,

Tony C.

 

Sounds like the centrifugal clutch is slipping ..

 

To update - I just rode the bike for a long time (prolly longer than it's been run in the last 10 yrs, lol), readjusting the clutch a couple times. My adjustments improved the clutch a little, but its still slipping badly at speed. Just before I shut it down, I was in 5th in low range at like 20 mph when I heard something snap. I thought it was the chain, but it downshifted fine and still goes through the gears smoothly. I am planning on replacing the centrifical clutch plates and springs, but I'm worried about the primary clutch. Should I replace that as well? Can anyone post pages from a shop manual on the removal and replacement of the clutches?

It was so great to get some seat time on the bike, and I need to get it fixed to 100% before I have my back operation in September ( ruptured L5-S1 disc, bone on bone there, along with 2 laminectomies.....[img]i/expressions/face-icon-small-sad.gif[/img]). Thanks for the great info everyone.......

Tony C.

 

PM your email address and I will email you the clutch section from the 1982-83 ATC200E PDF shop manual ..