3AJ clutch doesn't disengage and other woes...
Over the last few months I've been building a 3AJ I bought off ebay in bits. I'm pretty mechanically minded but have never owned a bike before and certainly never done anything this involved. So eventually the thing is in one piece instead of many but the damn thing won't start. Most of the problem here seems to be the clutch not disengaging properly:
When building the bike I couldn't find neutral, move through more than 2 gears or disengage the clutch. I took the cover off, separated all the clutch plates out, oiled and replaced. This at least meant I can rattle through the gears and find neutral, but not trigger the neutral light or neutral relay for the starter.
I have adjusted the clutch cable to maximum and it frees off a bit, but not enough. Also, it won't start on the button in neutral without the relays clicking it off immediately - overcurrent I guess. I'm charging the battery now to see if that does anything, but I'm not hopeful.
My mate gets very tired trying to push start it too and so I haven't had much of a go at that:-/
Getting a bit frustrated now, ideas?
Pictures for the curious at:
http://www.flickr.com/photos/4981785...7594237835258/
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