Remove the clutch pressure plate again check the condition of the the bolt/spring holes to make sure they are not broken, if all is ok there do the following:
Remove 3 friction plates and 3 steel plates
Refit the pressure rotating it until you get the correct position. Mark this position, you will know it as the pressure plate will go in about an extra 5mm.
Remove the pressures plate and replace the steel and friction plates in the correct order.
Replace the pressure plate in the marked position and replace the springs and bolts. Tighten the bolts in a criss cross manner to 8nm
Replace the gasket and clutch cover ensuring the dowels are in place and tighten all bolts to 12Nm
Now screw the cable adjuster at the handle bar all the way. Maximum slack on the cable.
Remove the rubber bung on the Sprocket cover, undo the locknut and screw it out to the end but allowing space for the screwdriver to fit.
Hold the clutch lever in lightly and screw the adjuster in and you will feel the clutch lever moving out to its home position. when it reaches its full home position wind the adjuster screw back one one full turn. Lock it up with the locknut.
Set the final position of the clutch lever to about 5mm of play between the end of the lever and the holder,
See pic of area I am relating to (found it on the web, saved me photographing it)
http://californiascooterco.com/blog/wp-c...stment.jpg
Let me know how you get on
Remove 3 friction plates and 3 steel plates
Refit the pressure rotating it until you get the correct position. Mark this position, you will know it as the pressure plate will go in about an extra 5mm.
Remove the pressures plate and replace the steel and friction plates in the correct order.
Replace the pressure plate in the marked position and replace the springs and bolts. Tighten the bolts in a criss cross manner to 8nm
Replace the gasket and clutch cover ensuring the dowels are in place and tighten all bolts to 12Nm
Now screw the cable adjuster at the handle bar all the way. Maximum slack on the cable.
Remove the rubber bung on the Sprocket cover, undo the locknut and screw it out to the end but allowing space for the screwdriver to fit.
Hold the clutch lever in lightly and screw the adjuster in and you will feel the clutch lever moving out to its home position. when it reaches its full home position wind the adjuster screw back one one full turn. Lock it up with the locknut.
Set the final position of the clutch lever to about 5mm of play between the end of the lever and the holder,
See pic of area I am relating to (found it on the web, saved me photographing it)
http://californiascooterco.com/blog/wp-c...stment.jpg
Let me know how you get on