Clicking clutch

Information related to the Harris Matchless (also known as Devon Matchless)
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Clicking clutch

Postby Baldybiker » Sun Apr 14, 2019 2:10 pm

On my very low mileage (not yet run in, it's true!) Devon Matchless I find the clutch manifests a loud click when pulling in the clutch lever.
This happens when the engine is running or not.
It seems to function perfectly will although is heavy which may be normal?
Is this a thing? (as the millennials say).

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Re: Clicking clutch

Postby dave16mct » Sun Apr 14, 2019 7:07 pm

You could ask Gary at Sportax for advice. https://sportaxracing.co.uk
He works on Rotax engines all the time. He sells a teflon-lined clutch cable but you'll have to check with him if it will fit your handlebar lever.
Dave.

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Re: Clicking clutch

Postby Baldybiker » Mon Apr 15, 2019 12:41 pm

Ah, fitting at the handlebar lever, that's another story, which I won't bore you with.

Funnily enough I phoned Sportax (I've only contacted them a few times but I find them very pleasant and helpful) this morning and was given some possibilities. However, ultimately it was thought if it's not graunching just run it, so that's what I'll do for now. Maybe I'll take a gander when I service it. Appreciated.

Thank you very much for taking the trouble to reply Dave.

Just off for a ride in the sun :-)

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Re: Clicking clutch

Postby ushbert » Mon Apr 15, 2019 6:05 pm

Glad to see that you have a response to the clutch query. I was coming on with the intention of suggesting that you spoke to Force Motorcycles, whose main interest is the Rotax-engined Armstrong/CCM military bikes. I get all my Rotax parts and advice from them.

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Re: Clicking clutch

Postby dave16mct » Mon Apr 15, 2019 7:32 pm

Force are good but they only sell standard MT350/500 parts/bikes. Sportax specialise in all bikes with Rotax engines. Rebuilds, tuning, updates etc. Gary was an army mechanic working on the MT350and 500 for 18 years He also races an MT mosts weekends, so he really knows his stuff. I have an MT350 and I've had all my spares from Sportax.
Dave.

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Re: Clicking clutch

Postby Baldybiker » Sun Apr 21, 2019 9:18 am

Thanks for the replies folks, very grateful.

I have found that there is something awry with what might be called the pressure plate actuating mechanism so have learned how to remove timing gears, clutch etc. Have also replaced clutch plates as advised by Nick at Force. Not so sure about putting the timing back properly though. Still, will order parts after Easter.

BTW, the book says to 'stick' the rubber gasket of the sump to the metal filter screen, is there some kind of special adhesive?

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Re: Clicking clutch

Postby dave16mct » Sun Apr 21, 2019 1:54 pm

The actuating mechanism is similar to the burman B52. It has 3 balls which rise up when the lever is pulled. There are 2 types of return spring, one's a leaf spring, the other is a normal coil spring. They can both break and a ball can drop out, causing the stiff clutch and loud click. I didn't think your's would've suffered this as its such a low mileage.
You need a good puller for the bottom pulley. You can make the puller for the top one. You need a tool to hold the clutch and one to adjust it afterwards. The timing is very easy, but make a note of the marks on the pulley and cam. Then later just line everything up with a long straightedge. I don't remember putting anything special on the sump plate gasket. While you've got the timing cover off make sure the tiny hole at the bottom is open and don't forget to mark which way round the timing belt goes or better still replace it. Have fun! :D
Cheers Dave

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Re: Clicking clutch

Postby Baldybiker » Sun Apr 21, 2019 7:35 pm

The Burman, interesting.
Yes Dave, three balls and a triangular plate with an arm for the cable, mine has a coil spring. There is also a flat high tensile looking spiring opposite this which I lifted very lightly and it snapped immediately. Maybe the weakness caused the problem.

The timing belt has to go a particular way round? Is that just because of the way it wears? I do have a new one to fit.
I must look for that tiny hole you mention, didn't notice that.

Grateful for your input,

Stephen.

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Re: Clicking clutch

Postby dave16mct » Sun Apr 21, 2019 7:54 pm

No the belt only has to go the same way it came off. If fitting a new one, anyway round. Only fit a good one from Force or Sportax. Dayco are the best. Yes the hole at the bottom is very small but important to keep it clear, it soon clogs up with mud etc. Water stays in there and the bottom pulley goes very rusty. Have you been on here yet?:
http://www.mtridersclub.co.uk/viewforum.php?f=39
Everything Rotax on here!
Dave.

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Re: Clicking clutch

Postby Baldybiker » Mon Apr 22, 2019 11:38 pm

I got my parts from Force on this occasion. I think the belt is Dayco, I’m pleased to note.
I’ll sign up on mtriders, sounds good.
Thanks for your tips and help Dave.
Stephen.

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