Author Topic: S6 - Heavy working Clutch and problem to dismantle Flywheel  (Read 322 times)

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Offline douglas1947

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On my S6 I have changed the clutchlever to internal bowden cable.
It was not easy to fit the new cable to the clutch lever behind the flywheel, but I had managed in the end.
Now the lever is very hard to pull and the clutch do not work perfect to free the engine from transmission.

I can not pull off the flywheel, there is NO Exractor Ring as on Douglas Drawings.

Im afraid on my bike is something missing or wrong. I have added aphoto of the Flywheel Nut.

I hope someone can help.

Michael


Offline Doug

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Re: S6 - Heavy working Clutch and problem to dismantle Flywheel
« Reply #1 on: 19 Jul 2017 at 14:57 »
Michael,

This is a like to a post showing the flywheel nut and the standard jam nut ring / flywheel extractor.

http://www.douglasmotorcycles.net/index.php?topic=5138.msg18551#msg18551

Lacking one of those rings, you need to borrow an extractor like the one shown in this post:

http://www.douglasmotorcycles.net/index.php?topic=6276.msg23204#msg23204

However if the only thing that changed from before was the inner clutch cable, it sounds like it was too large for the outer casing. They need to be a sloppy fit, especially if there are tight bends in the outer casing.

-Doug

Offline douglas1947

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Re: S6 - Heavy working Clutch and problem to dismantle Flywheel
« Reply #2 on: 19 Jul 2017 at 17:55 »
Thanks for the reply.
Doug, you think the flywheel nut is not the original and I should try to make a special extractor, as show on the 2nd of your photos.

I do not know, what is going wrong with the clutch operating mechanism, when I had changed the Bowden cable.

Michael

Offline Doug

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Re: S6 - Heavy working Clutch and problem to dismantle Flywheel
« Reply #3 on: 19 Jul 2017 at 22:14 »
Michael,

Your flywheel nut looks original; even having the clipped corners to make space for the lock/extractor ring nut.

The problem with making an extractor, either the ring type or the type with the jack screw, is that it is much easier while the flywheel is off the engine and available to use as a thread gauge to test the size! Hence seeing if you can borrow na extractor already made for that series flywheel.

-Doug

Offline douglas1947

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Re: S6 - Heavy working Clutch and problem to dismantle Flywheel
« Reply #4 on: 20 Jul 2017 at 11:19 »
Hi Doug,

thanks for your answer.
I do not know anyone to ask for an extractor.
I should open again the flywheel to have a look to the thread.
May be 20G is usuall?

Michael

Offline Doug

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Re: S6 - Heavy working Clutch and problem to dismantle Flywheel
« Reply #5 on: 20 Jul 2017 at 12:35 »
The thread is 1-1/2 x 20 threads per inch. -Doug

Offline douglas1947

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Re: S6 - Heavy working Clutch and problem to dismantle Flywheel
« Reply #6 on: 20 Jul 2017 at 12:42 »
Doug,

many thanks!

Michael

Offline douglas1947

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Re: S6 - Heavy working Clutch and problem to dismantle Flywheel
« Reply #7 on: 06 Aug 2017 at 16:16 »
Hi,
I have sorted out the problem.
When I got off the flywheel (with an extractor) I found the 3 steel rollers for the clutch mechanims had flat worn parts on the surface.
This caused a sliding and not a rolling movement, and this makes the clutchworking so bad.
I have changed the rollers; rollers of a 5/8 x 1/4 chain do fit!

Michael