• APOLOGIES FOR RECENT REGISTRATION PROBLEMS! PLEASE TRY TO CONTACT US OR REGISTER AGAIN. ALL FIXED AND GOOD NOW! Rejected or didn't receive your confirmation email? Hit the Contact Us link at the bottom of any page to send us a message. We'll get you sorted. ~Jerk

Hunter 350: My Upgrades and My Troubles

ValorSolo said:
Thanks Data, this was very helpful.
Click to expand...
You obviously haven't been able to ride the bike if the clutch is still not working. Put the bike in 3rd gear, engine off, then push the bike with the clutch pulled in. Get someone to help push. This will likely unglue the clutch. I'm assuming the clutch has been adjusted correctly. Once you break the "stiction" of the clutch discs caused by overfilling the oil it should rapidly start to function normally if you get the motor nice & hot. And I'm assuming there is nothing else that you did to the motor that may be causing the clutch issue. Good luck, let us know how it goes.
 
Data said:
You obviously haven't been able to ride the bike if the clutch is still not working. Put the bike in 3rd gear, engine off, then push the bike with the clutch pulled in. Get someone to help push. This will likely unglue the clutch. I'm assuming the clutch has been adjusted correctly. Once you break the "stiction" of the clutch discs caused by overfilling the oil it should rapidly start to function normally if you get the motor nice & hot. And I'm assuming there is nothing else that you did to the motor that may be causing the clutch issue. Good luck, let us know how it goes.
Click to expand...
I did have the RH cover off during the cam install. Everything seemed to go back together fine.

And I will definitely try your suggestion in the morning. Thanks again.

Just in case, if I'm not able to get help or push it myself in 3rd, would 4th or 5th work?
 
Neil Samui said:
Did you take the clutch cover off when you did the cam install? If so, are you sure you sure you reengaged the clutch release properly?
Click to expand...
Yes, I removed the RH cover. That's where the clutch is on the Hunter. That's also where the crank lock tool is used.
But no, I'm not sure I've done correctly. After removing all the cover bolts, I had to move the clutch arm a bit for the clutch to release the cover.
 
In view of this further clutch info, I'd say don't try to push the bike as I mentioned earlier. Instead you need to further investigate & maybe to dismantle the clutch cover & examine what you've done. Whilst overfilling oil can cause a clutch stiction issue it may not be the case here. It might just be that the clutch operating mechanism isn't correctly assembled. Or it could just be the operating arm incorrectly installed but you must check. Good luck!
 
Data said:
In view of this further clutch info, I'd say don't try to push the bike as I mentioned earlier. Instead you need to further investigate & maybe to dismantle the clutch cover & examine what you've done. Whilst overfilling oil can cause a clutch stiction issue it may not be the case here. It might just be that the clutch operating mechanism isn't correctly assembled. Or it could just be the operating arm incorrectly installed but you must check. Good luck!
Click to expand...
I've ordered a new side cover gasket, among other things, from Hitchcock's.
Once they arrive, I will tear into it and see what's up.
 
Very good video. But after watching it, I don't think that it is my issue.
I aligned the clutch shaft just as he did. I think I'll tear it down, anyways.
 
This shows the limitations of the TDC tool?
Dropping the oil, removing the cover and gasket just to find TDC!
I prefer the Himalayan system which although less accurate is far quicker.
A better system for setting TDC is my new task. :unsure:
 
Once the cover is removed, what steps should be performed for troubleshooting?
Like if the clutch is sticking because of too much oil, what can I do to test/fix it?
 
I verified TDC with a straw in the spark plug hole. It was correct.
I used a different set of feeler gauges, they were very loose.
I adjusted to the new set, so hopefully that fixed the valve rattle.

I got the top end all back together, about to remove the RH cover.
 
Everything was installed properly inside. All put back together now.
Still no clutch. I haven't added oil back to it yet. What can I try now?
I put it in third and tried to push it. Didn't make it very far, though.

I'll leave the oil out until I hear back some suggestions.

And thanks everyone for all the help.
 
27177

I've been installing and uninstalling different accessories to see what I like.
I wanted to like the rear rack on there, but it didn't look right, fenderless.
Ended up with just the grab bars on. I think this setup looks awesome.
Aesthetically, I think this is the final version. No more mods for looks.

Unless you count the exhaust, I'm wanting to add, as aesthetics.
Well, I forgot about the mirrors I ordered but never received.
BLACK ROUND BAR END MIRROR FIT FOR ROYAL ENFIELD HUNTER 350 & METEOR 350 | eBay
27179

If they actually ever show up, I'll install those.
 
Last edited:
  • Like
Reactions: 2LZ
ValorSolo said:
Everything was installed properly inside. All put back together now.
Still no clutch. I haven't added oil back to it yet. What can I try now?
Click to expand...

Take the lever off and move it back a couple of splines...there is a casting mark on top of the casing, the lever should be inline with this so that you get the right amount of travel when the clutch lever is pulled to disengage the clutch.
 
Neil Samui said:
Take the lever off and move it back a couple of splines...there is a casting mark on top of the casing, the lever should be inline with this so that you get the right amount of travel when the clutch lever is pulled to disengage the clutch.
Click to expand...
This was it, kinda. I had the lever aligned with the mark.
But I was putting the "slack" counterclockwise, backwards?
Just dumb on my part. It's always the simple things that get me.
After taking the slack all the way clockwise, the clutch works.
You can't learn by doing everything right.

Also, the valve rattle is gone. She's purring like a kitten.
Funny thing, the bad feeler gauge came from NAPA.
The good set came from Harbor Freight.
 
Quick question. Checking the oil. Will the new front tire, 7 inches taller, effect the level I should be seeing?
I would think so, if only slightly. I assume, as long as I measure the oil I'm adding correctly, it should be fine.
 
You must log in or register to reply here.
Top Bottom