Transmission/push rod issue

[111]

anyone have much experience taking your clutch apart? I've never done it before.

So I am usually pretty good with mechanical stuff but I really screwed up. I was replacing the front sprocket on the bike and when I went to put the cover back on I think i put too much pressure on the push rod and possibly damaged something in the clutch. the push rod goes in an butts up against something but seems too far in therefore not allowing me to disengage the clutch.

I was thinking of pulling the clutch apart. Any help is appreciated.

[shilka99]

Which bike is this on?
I rebuilt the clutches in my KTM, Ducati and VFR just recently. Many others not so recently. I'd be happy to help wherever you need it.

[111]

12 gsxr 600

[Rhino]

Remind me to never buy a GSXR and try to work on it myself. Seems ridiculously easy to fuck them up, even when you know what you're doing.

[milesmiles]

Have all of your washers on there? Sounds like a simple question, but it's hard for me to see how changing a sprocket could damage the clutch?

[milesmiles]

Oh and I should mention that one of the washers on
My triumph(when changing sprockets) has an indention that has to go on the correct way.

[111]

Agreed. Why the hell you would engineer a bike in such a way is beyond me.

Remind me to never buy a GSXR and try to work on it myself. Seems ridiculously easy to fuck them up, even when you know what you're doing.

[111]

Yeah everything seems to be on properly.

Have all of your washers on there? Sounds like a simple question, but it's hard for me to see how changing a sprocket could damage the clutch?

[milesmiles]

For some reason it won't let me copy the link, but type this below in google. Them the"perthsportsbike" link talks about this issue

damaged push rod gsxr sprocket change

[111]

yeah, I saw that last night.

I'm just debating taking it apart myself or taking it to swiftys. I don't think it will be hard to take apart but it will be more of a question of what to look for. The experience would good.

[111]

HELP

So when I took the cover off, the tabs of the outer plate(big red arrow) there were resting on the outside of the metal housing(small red arrow) and they popped into where they are pictured here when i went to remove the springs. However, the best i can tell it should be where the green arrow is pointing. Any input?

[fixxervi6]

Can't tell from the picture but it's possible that is right? looks like it has room to move.

[111]

was just able to verify in the service manual that the alignment is right.

[111]

So it looks like what happened was when I went to put sprocket cover on i put pressure on the push rod to the point that it depressed the clutch so far that the outer disc ended up resting on the outside of that housing. I have nearly everything back together and it appears to be functioning correctly.

All I have to do at this point is put the cover back on the transmission. The Gasket I have now looks fine but I might as well put a new one in. Any suggestions on how to seal it up properly?

[fixxervi6]

New gasket is a MUST, just throw it on there and tighten it down.

While you have it apart, I would recommend adjusting your slipper, the stock setting doesn't release soon enough imo.

[111]

While you have it apart, I would recommend adjusting your slipper, the stock setting doesn't release soon enough imo.

I think every stock setting I have changed on the bike has made a world of difference. Another reason I don't trust stealerships.

[shilka99]

Another reason I don't trust stealerships.

**Threadjack** I keep trying to support local businesses but every single time I've spent money at a dealership in the last 5 years they've screwed me over either directly or indirectly. My insurance for the RSV4 is yet another in a long line of mistakes made by dealerships. Mechanical work has been even worse. I say do the work yourself and even if you make mistakes you'll only make them once and you'll learn every time.

[fireblade]

My insurance for the RSV4 is yet another in a long line of mistakes made by dealerships.

how did they mess up your insurance?

[shilka99]

I bought insurance through the local dealer instead of through the insurance company website. Big mistake.
When it was time to renew, the agent at the local dealer told me "Send me a check for $x and you'll be covered through next August. So I did. Then 2 weeks ago I get a notice in the mail from the insurance company saying I owe $300 extra. I call the agent, as its not August, and she says, "they're installing a new computer system and it hasnt caught up yet. Ignore the notice, you're covered till August".

Then, 2 days before the track weekend I was planning to attend, I receive a notice saying my insurance has been cancelled and it will cost another $300 to reinstate it. So I call the agent again and she says "Thats not possible, let me see whats going on. "

3 hours later the agent calls back, and immediately starts to apologize. Apparently she screwed up and told me the wrong initial amount. Even though the notices I received were wrong and the computer system really was sending out incorrect bills, the agent didn't know how to use the new computer system so told me the wrong amount when she told me how much to pay to be covered through August.
She admitted fault, then said "so how would you like to pay that $600?"

I'm not going to pay $300 to reinstate insurance that was cancelled due to a mistake made by the agent. and I'm not going to buy insurance from a company thats so screwed up neither they nor their agents can use their computer system.

I was all set to be really pissed off by this when the buyer for my 996 calls and says he can only come pick it up on the saturday I was planning to ride. Then on saturday he flakes, apologizes and says he'll come sunday. Both riding days gone. Then guess what - he spends all day Sunday in hospital instead of coming to give me money.
Wasted weekend. Inept local dealership selling insurance from an incompetent insurance company.

Rant off. Chest unburdened. Now you see why I didnt go into detail earlier.

[111]

Got it all put back together today and did a test drive. The -1 added some life to the bike. I definitely need to get a speedo healer before I get myself into trouble.

[Rhino]

Got it all put back together today and did a test drive. The -1 added some life to the bike. I definitely need to get a speedo healer before I get myself into trouble.

With -1 in the front, your speedo should be reading significantly HIGHER than your actual speed. Keep the indicated at the speed limit when cops are around and you'll be going slow enough to avoid tickets (and piss off everybody behind you).

Now if you're using your new found torque at the rear tire to loft the front tire a bunch, no speedo healer will help and all bets are off with the cops.

[fixxervi6]

I'm considering -1 but I'm worried about how much it will impact my cruising mpg

[111]

Loft the front tire.....on take off, occasionally. Riding wheelies...believe it or not I've never done that.

Speedo definitely reading higher as expected, but that isn't the problem. It's the torque I didn't have before that is getting me to speed more easily. The low end torque really sucked before, IMO.

I'm considering -1 but I'm worried about how much it will impact my cruising mpg

I don't think it will make that much difference, but I can let you know what I experience. Where I usually notice a difference is in how aggressive I drive.

[Stardog]

I'm considering -1 but I'm worried about how much it will impact my cruising mpg

I did -1/+2 like your meatball SHOULD HAVE DONE and I got the exact same MPG as Telomere (OK I burned 1/10 of a gallon more) over the course of 110 miles, I was riding it harder and I am like 100 pounds heavier. RPM does not necessarily burn fuel.

[DarcShadow]

But what did you get before the change.