Zane Clutch Issues

Cosi

Cosi

Hero member
Location
Kingscliff
I have a Diamonte that came to me with a rattly clutch, no its not mine and remember chaps this is the technical section so no need to fill it with shit about how awseome Zanes are.  It came half pulled apart so i never got to hear it running, anyways i pulled the clutch apart and discovered that it was missing two of the shims under the bellhousing and the driving plate, they werent much, only 5.8mm in total, shouldnt matter too much.....

So the problem now is that the rear wheel is locked, i can select all gears and find neutral on the mainshaft but the counter sprocket dont want to move. My first thought was its the sprag, I havent pulled it out yet to have a look but from what i seen so far on this "rebuilt" bike that has done 100ks, im not so sure, i hope its not more sinister 

Your thoughts appreciated
 
Hi Cosi, are you saying it is blocked even in neutral? I would pull the primary chain first. if then the backwheel moves and drives the clutch drum even in Neutral, I would assume it is a clutch issue. If it still doesn't move, I assume the gearbox has an issue (maybe assembled in the wrong way?). Piet has more experience with it, maybe he has an idea??!
 
haven't had the 500 or Zane engine appart, so - sorry if I mixed old and new technology...  ??? :-[ ???

In that case I'd check the primary drive gears. How far appart did you have the engine?
 
Hi Cosi,
Just wondering whether you have put the clutch back together incorrectly and it is now touching the inside of the main cover thus
locking up.
I know its possible old the older 500s.

Andy
 
The clutch is out still, all I did was rattle the nut off that holds the basket on, the clutch is completely out still

I can find neutral on the main shaft, the rear wheel remains locked, and no it's not the rear caliper seized
 
Cosi said:
The clutch is out still, all I did was rattle the nut off that holds the basket on, the clutch is completely out still
Click to expand...

What was done before that?  Finding neutral only means the shifter mechanism sort of works.

Half-loosened sprocket bolts fouling on the swingarm?

piet
 
It came with the primary off, clutch plates out, we wheeled it in and up onto the lifter, Pulled the basket and plate off,

I decided to give the wheel a little rock this morning, As you rock the wheel the mainshaft will move back and forward about 2mm each way, but I can spin the mainshaft by hand as if its in neutral,  my feeling is its internal

I don't know any other reason why it would be locked???? or is there something im missing

 
G'day Cosi

Assuming you have confirmed that the problem is in the gearbox rather than the rear wheel (take the chain off if there's any doubt) it sounds like it's engaging 2 gears at once - possibly a bent or broken selector fork, or maybe axial displacement of one of the shafts.

I'm not at all familiar with Zane engines (the above is just a general comment applicable to any gearbox) so no idea what the 5.8mm shims are that you mention*. However, 5.8mm axial movement is a lot in a gearbox. Easily enough to screw up the selector function.

*While trying to figure out where the shims are supposed to go, your reference to the "bellhousing" is more than a little confusing. I'm reasonably sure that a Zane Laverda doesn't have anything that resembles a bellhousing. Very few motorcycles have one, apart from Guzzi, BMW and one or two others.

Cam
 
Cosi,

You are aware that several gears are prone to breaking?  No hard and fast pattern, except the engaging dogs go AWOL... might be one just hanging on and jamming things.  Open the sucker.  Even if it does free up through some strange circumstance, I wouldn't feel well without knowing all is well inside.  A blocked gearbox at speed is not funny! ::)

piet
 
Yes mate im aware, just strange that it done it on the bench, I told him its best to pull it apart considering what I found in the clutch...

Thanks

Will keep you informed, wont be happening too soon I gat a RS 250 to prepare for racing in 6 weeks....
 
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