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D2 poney clutch

D2 poney clutch

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JackD6-5R
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Working on early D2-5J ,can't get poney clutch lever to over center and stay engaged ,have to hold in. Did some early ones not over center or is something wrong with the clutch? It turns main over when held in. Tried setting clutch both ways.
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Thu, Aug 26, 2021 12:31 AM
neil
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Possibly something wrong with it - it is supposed to over-center. My guess is that in adjusting in both directions, you either undershot or overshot the sweet spot. Doesn't take a lot to adjust it from not enough to too much. If you have the patience, you can adjust it one notch at a time all the way in, and then having counted how many notches, then go back that far then start adjusting again one notch at a time but this time outwards. It might take 10 mins but it could avoid an unnecessary disassembly
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Thu, Aug 26, 2021 5:11 AM
edb
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Reply to neil:
Possibly something wrong with it - it is supposed to over-center. My guess is that in adjusting in both directions, you either undershot or overshot the sweet spot. Doesn't take a lot to adjust it from not enough to too much. If you have the patience, you can adjust it one notch at a time all the way in, and then having counted how many notches, then go back that far then start adjusting again one notch at a time but this time outwards. It might take 10 mins but it could avoid an unnecessary disassembly
as Neil said, there is a very fine distance of one pin hole either way of being correct for the clutch to engage or not especially when the clutch fingers get worn and flat spotted.
If you turned the adjuster several holes clockwise or it was that way when you got it you now need to keep backing off the adjusting collar--suggest adjust it out to loosen the clutch engagement position so it does not lock over and advance until you get the resistance/lock over needed.
IF the clutch is adjusted too far in it will not lock over either just as you describe.
Either this or Neil's method will get you there.
Cheers,
Eddie B.
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Thu, Aug 26, 2021 7:42 AM
neil
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Reply to edb:
as Neil said, there is a very fine distance of one pin hole either way of being correct for the clutch to engage or not especially when the clutch fingers get worn and flat spotted.
If you turned the adjuster several holes clockwise or it was that way when you got it you now need to keep backing off the adjusting collar--suggest adjust it out to loosen the clutch engagement position so it does not lock over and advance until you get the resistance/lock over needed.
IF the clutch is adjusted too far in it will not lock over either just as you describe.
Either this or Neil's method will get you there.
Cheers,
Eddie B.
Go with Eddie's approach! : ) I forgot to take into account that you said it turns the main over when held in. That indicates that the clutch is definitely making sufficient clamping force, so if it doesn't over-center, then it's probably too far in, so work your way out, one notch at a time. I found after adjusting my clutch post-reassembly, I had to adjust it a couple of times as it "bedded" in, so you might find this too. One way to check if it's too slack is if you leave the compression engaged, and try to engage the clutch, if it makes a poor half-hearted attempt at turning the main, you might need to tighten it up a bit, even if it over-centers ok
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Thu, Aug 26, 2021 10:59 PM
JackD6-5R
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Thanks for the replies . I will keep trying to get it adjusted. Thanks again.
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Fri, Aug 27, 2021 7:50 PM
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