broken my clutch/ advice please.

[lumpyv]

im really quite fed up with this latest reminder of why I should,nt mess with motorbikes.

got off work early so thought I would clean the bike a bit.

I gave the chain/rear sprocket a good clean and thought the front cog under the cover must be really filthy too. I was convinced I had had the front cover of before with no issues so I unbolted it all and gave it a little tap. Off it came .

located just to the left of the front cog , as you look at it, the dome ended shaft has slipped out a touch and now wont go back in far enough for me to get the housing back on .

clutch lever will now not operate..

what have I done?? is it going to be expensive?? any advice gratefully received.

thinking about it it was my old Yamaha that I had the front cover off with no problems.

now got to go out so I cant answer any replies for a bit but thanks anyway.

[AMCQ46]

the clutch slave cyl has mover out under the pressure of the fluid........... you should force it back in with a G-clamp, then fit it as normal

[VTRDark]

First off did you remove or tie back the clutch lever before removing the sprocket cover. If not, then the Clutch will require bleeding again.

You have not broken it so don't panic. The dome end shaft as you call it runs between the clutch and the clutch slave. The reason it wont fully retract in is because your pushing against the clutch on the other side. Put the cover on, making sure that the domed shaft fits in the hole for the slave cylinder. You should be able to get a couple of turns on the bolts to hold the cover on. Tighten these up a bit at a time jumping from one bolt to another so it tightens down evenly. There will be some resistance as it pushes the rod and compresses down.

(:-})

[lumpyv]

First off did you remove or tie back the clutch lever before removing the sprocket cover. If not, then the Clutch will require bleeding again.

You have not broken it so don't panic. The dome end shaft as you call it runs between the clutch and the clutch slave. The reason it wont fully retract in is because your pushing against the clutch on the other side. Put the cover on, making sure that the domed shaft fits in the hole for the slave cylinder. You should be able to get a couple of turns on the bolts to hold the cover on. Tighten these up a bit at a time jumping from one bolt to another so it tightens down evenly. There will be some resistance as it pushes the rod and compresses down.

(:-})

hi carl, no I did not tie the lever back.

if it only needs re bleeding that's not too bad. when the pressure is released I take it the rod will go in easily ??

cheers

[AMCQ46]

when the pressure is released I take it the rod will go in easily ??

cheers

sound like a job for Lloydie and his lube

[lumpyv]

when the pressure is released I take it the rod will go in easily ??

cheers

sound like a job for Lloydie and his lube

as I typed that I did wonder who would say something

luckily im some distance from the big L

[lumpyv]

now got the fluid out and with the bleed nipple open and the cap off the reservoir the rod still is going nowhere.

I can get all of the 5 bolts to make individually but not all 5 at once so no point in attempting to apply pressure that way because the cover will break.

ive tried to push it in with a bit of wood with the cover off but it really has no give at all?


there is not really any way you can get a g clamp on it as access is restricted..

what is at the other end of the rod?? could something have dropped which is now stopping it going back?. the drawing in the Haynes manual doesn,t really make it clear?

[thunderbolt]

It seems to me that you need to force the piston back into the clutch slave cylinder to provide enough clearance the refit the cover.

You have to provide a way for the fluid to be removed from the cylinder as you push the piston back in. So undo the bleed nipple, fit a piece of plastic clear hose to it and push away. Once the cover is on just bleed the slave cylinder as per usual.

Hope this helps.

[lumpyv]

It seems to me that you need to force the piston back into the clutch slave cylinder to provide enough clearance the refit the cover.

You have to provide a way for the fluid to be removed from the cylinder as you push the piston back in. So undo the bleed nipple, fit a piece of plastic clear hose to it and push away. Once the cover is on just bleed the slave cylinder as per usual.

Hope this helps.

thanks TB but I think I have done this. the bit im talking about is the pushrod that goes acrossways through the engine . its about 7 inches long I would guess but I haven't pulled it completely out, it locates into the housing/chain cover that I have foolishly removed.

there is virtually no hydraulic fluid left in the thing? I have pushed the rod so hard it has nearly come off the paddock stand !

[MacV2]

It seems to me that you need to force the piston back into the clutch slave cylinder to provide enough clearance the refit the cover.

You have to provide a way for the fluid to be removed from the cylinder as you push the piston back in. So undo the bleed nipple, fit a piece of plastic clear hose to it and push away. Once the cover is on just bleed the slave cylinder as per usual.

Hope this helps.

thanks TB but I think I have done this. the bit im talking about is the pushrod that goes acrossways through the engine . its about 7 inches long I would guess but I haven't pulled it completely out, it locates into the housing/chain cover that I have foolishly removed.

there is virtually no hydraulic fluid left in the thing? I have pushed the rod so hard it has nearly come off the paddock stand !

You have PM...

[VTRDark]

I may be worth removing the slave from the sprocket cover and give it a good clean out while you in there!!! Then put the sprocket cover on first and then the slave. You can safely remove the rod if you want, but note it has different end's, so make sure it goes back in the right way around. While it's out roll it on a flat surface to double check it's not bent/bowed.

(:-})

[freeridenick]

This sounds like exactly the problem I have except the sprocket cover is in place on my bike.

Clutch slave cylinder has been bleed dry and I still can't get the slave cylinder on far enough to get the three mounting bolts on their threads. At best I can get one to bite.

It's almost as though something has slipped and the rod won't go far enough into the clutch. The piston is almost flush with the housing, so I think the slave cylinder is OK. Do I just keep nipping the bolts up? Doesn't feel right.

[lumpyv]

This sounds like exactly the problem I have except the sprocket cover is in place on my bike.

Clutch slave cylinder has been bleed dry and I still can't get the slave cylinder on far enough to get the three mounting bolts on their threads. At best I can get one to bite.

It's almost as though something has slipped and the rod won't go far enough into the clutch. The piston is almost flush with the housing, so I think the slave cylinder is OK. Do I just keep nipping the bolts up? Doesn't feel right.

sounds just like my problem. I think if I applied a bit more pressure I could crack the housing dead easy ..

[lumpyv]

yee-har I have got it back together again, not bled it yet but as you all said it is not the rod that needs to go in further its the piston that needs loosening up/retracting.

I took the slave cylinder off the cover and g clamped (see what you meant now al ) it in a bit. used a socket slightly smaller than the face of the piston so pressure was exerted evenly.

thanks for the advice and to wicky for offering to pop round and to mac for his telephone helpline service.

good luck freeridenick if you are still having probs. hope the above helps

just got to bleed it now

[freeridenick]

Great. I'll give it a go next week.