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HELP! Clutch not disengaging! CB400F

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zombie365:
Hi All,

Just come to the end of my CB400F cafe racer build. I’m having trouble with the clutch.

The clutch is not disengaging. The bike starts perfectly fine when in neutral.

If I try and start engine whilst in gear whilst pressing clutch lever, the bike jumps forward as if the clutch isn’t pressed.

When bike is in gear with engine OFF, I rock the bike backwards and forward the back wheel is engaged with engine, there is no difference if clutch is pressed or not.

Kickstart will not engage either, it springs back into position, but it won’t engage properly to turn the engine over. Only tried kickstart when in neutral. Maybe this is related?

The engine has been stood dry for the past year whilst building the bike.

I did remove and refit the internal kickstart mechanism as it fell out when I took engine case off for refurb.

I have adjusted clutch cable so that it reaches max leverage on clutch arm, therefore clutch should definitely be disengaged.

Any things I can try before I start disassembling?

Any help would be appriciated!

Cheers,

Sam

Oddjob:
No, disassemble. You'll clearly fitted something wrong. Try and remove all the clutch plates and see if any are stuck together. Kick start is clearly not fitted right or it would work.

TrickyMicky:
Cannot help re. the kickstart problem, but, when my bike was put back on the road after 9 years the clutch would definitely not free off. Rather than dismantle the clutch cover etc., I clamped the handlebar lever in the release position, removed the dipstick, then the clutch is visible. Very gently with a flat bladed screwdriver it is possible to carefully part each plate from its partner whilst turning the engine over a little at a time. Be luck, Mike.

McCabe-Thiele (Ted):
I agree with Ken you need to disassemble the side cover and check out the two mechanisms.

Did you seperate the clutch plates before you put it back together - they can as you probably know stick together easily when left standing?

The clutch has that odd plate holding the 3 balls, plunger etc might be an issue there somewhere with an incorrect spacer fitting.

The kickstart should be straight forward to check - the spring can be fidly.

Nurse Julie:
Have you put #115 in the correct location, a lot of people don't.
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