Might be a bad throwout bearing. Even though you see some movement in the clutch pack, odds are it's not releasing completely, in order for the clutch too fully engage.

The ramp is in the tranny side cover with the clutch cable connecting to it. It pivots and extends, pushing on the rods connected to the throw out bearing in the clutch pack to fully disengage clutch. Ramp could be jammed up and stuck. Typically this would give you a floppy clutch lever.

 

My moneys on the clutch hub splines starting to be completely wiped out. The intermittent goes into gear is that not all the splines are completely gone yet.

 

What would cause clutch hub splines to wear away? And wouldn't they shear away fairly quickly causing a ton of metal in the primary?

David

 

Yes and no! hub can either immediately shear or rock back and forth until the teeth are low enough to finally shear. Lot of variables like driving habits (hammer drops, lugging, maintenance habits, and/or overloading the vehicle or big loads can contribute), (proper clutch adjustments, detecting early stages of failure) are a few. The result will be found in the teardown.

 

Thanks, Bagman. I've subscribed to this thread. I hope the OP posts back with the diagnoses.

David

 

Subscribed. I'm lost with this one. The fact that nothing changed over night, came back out and it worked fine is odd to say the least. Should that clutch plate be spinning when he rolls it like he said? Maybe having the cover off and messing with the clutch, he inadvertently fixed it temporarily, so problem must be there. You would think.

 

Hey all,
Loading up on trailer this Friday for transport to Indy. Will post diagnosis/fix

 

My guess would be the rubber isolators that absorb shock between the rear drive sprocket to the rear wheel. Raise the rear wheel, start bike, put in 1st gear and see if rear wheel spins. You may have to press on the tire as the lack of friction normally between the road and tire may allow the wheel to turn. If your belt and rear sprocket are turning and your wheel isn't that would be the problem. I believe there are 6 of these and cost between 3 & 4 $ each. Not a big job to change.

 

dropped off bike with Indy this past Saturday. just waiting for diagnosis......

 

Any updates?