Speaking of clutches...

[gregforesi]

I installed a new-to-me 76 engine in the bike and have about 500 miles on it now. When I pull away from a stop, and just as I let out the clutch the last little bit, there is a noticeable clunk as if the clutch dumps in rather than smoothly engaging the last bit.
Any advice on where to look? I've got the clutch from the 78 engine (and its B plate) sitting here in a box. Current clutch is adjusted per the book.

[jdvorchak]

Any roughness in the clutch cable? When you replaced the clutch plates did you sand blast the steels? Soak the new friction plates in oil for a while? Neglecting any of these will cause the problem you are experiencing.

[Track T 2411]

Are you sure it's not the output shaft? I know others have discussed a clunk from the shaft, but I've never experienced it, so I can't say for certain...

[jdvorchak]

Forgot the pivot pin and lever perch clean and lube? Also make sure cable routing is correct without sharp bends. New pressure plate springs? If old springs did you measure them for being within factory specs and all the same length?

[gregforesi]

JD, this engine has 4000 miles on it now. It's the original clutch, springs, et al.
The owner hit a tree in the spring of 1977. I suppose he had no insurance because he pulled the engine out of the frame and filled it with oil, and it sat in a garage in northern Michigan for 35 years. The engine took a wallop on the left side belt cover, bent the cam pulley, tensioner pulley and back plate. I've been into it. It's a real fresh engine, not broken in yet. Clutch cable is the same one, correctly routed.
I suppose I'll revisit the adjustment, but I have a feeling there is something not quite right inside.

Trackman, if it's the output shaft, then it won't get fixed until it needs a stator or something.

[ritalz]

Are you sure it's not the output shaft? I know others have discussed a clunk from the shaft, but I've never experienced it, so I can't say for certain...

I tend to agree. Do a search on 'half rotation clunk' or something like that.

[Whiskerfish]

yep half rotation clunk. I have had it to some degree on all my 1000's. I attribute it to the output shaft spring unloading.

[Rat]

Happens on some 1200s as well ....... at least one .......

Gord

[05c50]

My 78 has done it as long as I've owned it, but my 75 (with a 78 drive shaft) has never done it.

........Paul

[jdvorchak]

Ok sorry to hear about the history of the engine. So we can assume the engine was running at the time and came to an abrupt halt when the rear wheel stopped turning. That would put a lot of stress on the drive line I would guess. If I remember correctly all of the GL's have a shock absorber type of mechanism that took a big hit in the opposite direction of design. If you can live with it, ride it until you have the need or want to pull the engine and get into the transmission/output section.

[rcmatt007]

I am glad to know I am not the only one who thinks an "old-wing" can be clunky