clutch fails after sprocket change

I have just fitted a new chain and sprocket to my 2000 vfr800. I now find that the front sprocket cover will not seat properly. It looks like the clutch lifter rod is protruding 1/4 inch too much through the drive chain guide plate. I have tried to push the rod back towards the clutch side and it seems to be a far as it will go. Any idea how I can get it back the extra 1/4 inch??

 

Piston

Do you have the slave cylinder piston pushed in all the way?

 

I dont think you have the rod seated properly. When its in correctly it should just slide in with a little effort. Make sure your bikes transmission is in neutral (it might help). Or...you know what they say...if you cant fix it with hammer then you have an electrical problem.

 

the clutch slave was never removed from the sprocket cover. I have measured the lifter rod and it is too long for the clutch slave by about 1/4 or so. I think the rod needsto go back towards the clutch?

 

Thanks for that but the rod seems to be as far back as it will go but it seems to be 1/4 inch too far out.

 

ronald reagan our last great president....well we had a good run... 100 years from now, the people that do not exhist as of yet will say 'what they hell were those idiots thinking electing obama...' and they did nothing about it afterwards?? just let him socialize the country withing four short years...thank you hippies:thumbsup:

 

I think a temporary ban may be in order so I don't have keep seeing your posts cluttering up good threads... :crazy: Seriously man, go play in your own threads or go for a ride, sounds like you could use the fresh air.

 

Right on.
BTW Ronald Reagan tried to do away with Social Security too.
Guess he did not care if the streets were filled with old women his mothers age. He had his rich doctors wife.

ABOUT THAT CLUTCH ROD. Do not force it!!! Whatever you do.
Just remove the cover and make sure the rod goes in. I would actually remove the slave cylinder from the sprocket cover and THEN put the Slave cylinder on AFTER the sprocket cover is on. If you took the rod all the way out make sure that you put the Correct end into the engine.

 

I can tell by the marking on the rod that it's fitted correctly and is a far in as it will go. I have no itention of forceing it. Looks like the rod will not engage with the lifter piece and I will have to remove from the clutch side and insert the rod from that side. If anyone know better I would welcome their input. Thanks.

 

You can't get the sprocket cover on, right ?? And you pushed the slave piston in as far as possible ?

Try removing the speedodrive section of the cover.....something may be crossed up.

See if the cover goes on with the pushrod removed?


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{Regan dealt arms to Iran, prolonged the hostage crisis for his own political purposes, had the CIA transporting drugs to fund black operations, sent armed terrorists into Nicaragua to punish the population for electing a socialist government,supported Central American death squads, invaded soverign countries in violation of international law, subverted the US constitution regarding presidential powers, and much, much more.....Too bad Hinkley missed.}

 

Never heard of having to remove the clutch cover to get the rod to engage.
Usually there is a short lifter piece(a rod with flat disk on the end) the sits in the center of the clutch basket.
I would suspect that the clutch slave cylinder may need to be bled a little or something to get it to mate up. Did you try pushing in the piston into the slave cylinder to see if it is all the way in?

 

The rod sits about a 1/4 or more in the dimple that's in the clutch joint (on the other side behind the clutch pressure plate), it's not in the dimple most likely, tilt the rod up and down until it falls in the center of the dimple.

 

Thanks, I was hoping someone would know if I need to remove the pressure plate. AS I push the rod back in I can feel it engage with the lifter piece by about 1/4 inch. I am afraid to push/force the rod into the slave cylinder because I don't know how how much pressure to use.

 

Thanks, but as I push the rod back in I can feel it engage with the lifter piece by about 1/4 inch.

 

The speedo sensor is removed and it fits without the rod. Thanks

 

You didn't move the clutch handle while it was apart did you? I remember putting my front sprocket on my XX. I had to push the piston back in the slave cylinder a bit so it would go back on without forcing it.

 

I'm sure I never touched the clutch lever. Tomorrow I will dismantle the slave cylinder to check if the piston is fully back. Failing that I will have to bite the bullet and remove the pressure plate to check if the rod is fully in. Thanks again for all the contributions, much appreciated.

 

There is NO REASON to take apart the clutch.
You need to get help from a experienced mechanic.

It is UNECESSARY to take apart the clutch.
Part #11 the short rod in the clutch housing cannot escape. Check out the OEM parts diagram. There is no reason to take it apart.

 

+1....not a clutch problem


use a C-clamp to fully retract the piston


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be very careful not to overtighten the sprocket cover bolts; i've seen a few bikes damaged because fragile mounting points were pulled off the engine case by overtightening .



PHOTO: (broken mounting point is just above clutch pushrod)

VFR Discussion -> Gallery -> Viewing image -> IMG_0394.jpg

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PHOTO: (long bolt is held by only 2 threads)

VFR Discussion -> Gallery -> Viewing image -> IMG_0395.jpg

 

Armed with the knowledge that the solution lay with the slave cyninder I set about resovling the problem this morning.

I removed the slave cylinder from the sprocket cover and refitted the cover.
Could not the piston back any further even with the reservoir cover removed.

With the cover reinstalled I then decided to push the piston out by pulling the clutch lever, which seemed solid rather than soft as I expected. Making sure the piston could not be pushed out too far I yanked on the clutch lever. The piston "popped" out a fraction and the clutch lever could be pulled all the way to the bar. I was then able to push the piston way back into the slave but it would ease back out when I tried to fit it to the sprocket cover. Eventually got it on by pulling in the clutch lever while pushing slave into place on the sprocket cover. Everything now working perfectly. Many thanks for all the contributions.