HELP...Replaced clutch now bike won't start....

Please help me, I followed the steps to replace clutch, everything went great, but now the bike is hard to turn over almost like the battery is dead. It just goes ruh, ruh, click, click...the battery was fine when I started to do the clutch job...now all the sudden nothing....do I have the 5 spring bolts too tight or something, or could my batt. for some reason just die or lose charge. I had it running before I took it apart to get the oil warm. Please let me know. Please help...or call me on my phone [snip]<edit> Kurt.</edit>

 

Changing the clutch should not realy have had any effefct on starting, I don't think, unless you didnt put the new plates in the same way the old ones came out, and probably not even then. I'd venture to say your battery has lost its charge, which is an indicator of a couple of things. I suggest you put your battery on a charger overnight then do the following.

1) Check voltage with a multi-meter and make sure it has a voltage of about 12.89 volts. If so, proceed to step 2. If not, replace battery. Then proceed to step 2..
2) Install charged battery in the bike, test again for voltage, again about 12.89 volts.
3) Start bike.
4) Check idle voltage with a multi-meter, should be about 13.5 volts
5) Increase engine rpm to 5,000, watching the multi-meter. Voltage should increase to to a range of 14.5 to about 16.0 volts (according to the manual). If voltage is in this range, all is good, proceed to step 6. If not, regulator/rectifier is most likely bad and should be replaced. An OEM Honda unit or a Rick's Electrics one are my suggestions for replacement. Then proceed to step 6.
5A) NOTE: if battery and R/R check out, stator could be bad. Disconnect the stator at the connector (usually behind the right side cowl and is the 3 yellow wires). Using multi-meter, check for voltage (AC). Start bike, rev engine, voltage should increase up to about 75 volts. if at anytime the voltage drops, the stator is probably bad and should be replaced.)
6). Buy and install a volt meter, such as a Kuryakun brand. This will help you notice when the charging system is not doing it's job.
7) If you feel you like this is beyond your mechanical ability, and everyones level is different, take your bike to a trusted (key word is trusted) mechanic/dealer and have them check it.

Hope this helps and you get back on the road soon.

 

Vman thanks for the info...that for sure helps out other things maybe in the future. Reg thanks for the phone call you're a great guy with vast knowledge. Everyone what it was inside the clutch cover is the gear that meshes with the starter gear, and there is a think type washer that goes around the metal dowl that holds that starting gear in place...what had happened was I put the washer on the outside of the gear/dowl instead of putting it inside....got it all up and running, and it works great. Thanks everyone, and Reg thanks again for your priceless (well worth $300 to me) thread with pics for changing the clutch. Thanks again everyone.

 

Does anyone know how much oil I should put back in after changing the clutch. I think I put almost 4qts in. Maybe more like 3.5 or so. Its hard to read it on the dipstick cause its so clear or maybe I just am losing my mind....???? Anyone find it???

 

Another case where proper use of Honda service manual would have been advised, with expensive engine disaster narrowly avoided!

 

Glad to hear you got it fixed.