riteristrob
Expert Class
Posts: 109
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posted March 29, 2007 03:52 PM
Technical Clutch Adjustment Question- expert needed
Here's one for ya.................
02 zx12 clutch adjustment. Manual says 60 degress, I can only get about 52 degress for the angle between the two lines intersecting the point where the end of the clutch cable (at the clutch cover housing) bracket pivots on the clutch release lever, and the top of the clutch release shaft. Know what I'm talking about?
I have followed the Clutch Adjustment Inspection procedure in the manual, adjusting the clutch lever free play, 5-6 mm of threads showing at the lever adjuster, pushing the release lever foward, and measuring the angle.
I have adjusted the nuts at the release lever bracket to the max both ways, and the adjuster wheel at the lever to the max both ways, but can only manage about 52 degrees at the angle in question.
So, maybe my clutch is worn beyond adjustment, but I thought I would try to adjust it before pulling the cover and checking the plates.
I bought the bike last spring with 3000 miles on it. Owner said it had never been raced, but it was lowered about 3 inches in the rear, an inch on the forks, has a full Muzzy exhaust with a "run like a raped ape" PCIIIr map, and 17t front sprocket.
It seems like there is a bit of clutch slippage, or maybe it is wheel spin, and i'm not used to the power. Also, it seems that the angle would get bigger rather than smaller with wear.
So the question for the experts out there, I know you know who you are, is: how can I tell if the clutch is worn beyond adjustment without pulling the plates out and inspecting them? Is there some other procedure to determine if the clutch is worn beyond adjustment?
Thanks!
Rob
  
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twista
Zone Head
" Get up, and Stay up ! "
Posts: 797
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posted March 29, 2007 04:40 PM
if you have slippage,, like you just stated,, that is your problem,, your already ahead of the game having the 02 setup,, so spring for some stock steels and fibers and its a wrap,, i believe Mike might have a clutch pack left for ya ,, hit him up!
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" When in Doubt, There is no Doubt !"
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riteristrob
Expert Class
Posts: 109
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posted March 29, 2007 07:12 PM
Hey Thanks twista! I've never done a bike clutch. I have the sevice manual though, and looks relatively simple.
Looks like all I need are the steels, friction plates and a gasket, eh?
Do you recommend the OEM items or do you think aftermarket stuff, (Barnett, Versah or Muzzys), is better?
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twista
Zone Head
" Get up, and Stay up ! "
Posts: 797
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posted March 30, 2007 04:04 AM
i do mine and my brothers he has a 12 also,, it is fairly easy,, just make sure that the rounded edges that come off ,, go on the same way (on the steels,, also there is a big washer or spacer behind the hub it likes to hide,by sticking to it,, make sure all the parts are there and put er back together,, set your free play and your good,, usually i take the clutch cable holder on the cover off so i dont screw with the cable adjustment unless needed.. you shouldnt have a problem!
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riteristrob
Expert Class
Posts: 109
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posted March 30, 2007 06:18 AM
Thanks for the tips! I'll order up the clutch pack. Hopefully will have it by next weekend. Sounds like I need to find someone with an impact wrench to bust the hub nut loose. I've read about the cautions to keep it in neutral and do the 2X4 through the spoke trick.
I am recovering from shoulder surgery, and haven't been riding yet this year. The weather is getting decent enough, but the shoulder isn't quite there yet. So, I'm taking the opportunity to tweak and upgrade. Installed Galfer lines and pads, and will repack the muffler as soon as the re-pack kit arrives. I am so pumped to get on the beast again!
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twista
Zone Head
" Get up, and Stay up ! "
Posts: 797
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posted March 30, 2007 07:20 AM
i hear ya,, i am in the middle of getting her ready for the season also,, my brother and i cracked the nut loose with a breaker bar,, an impact makes life easy though,, good luck ,, just go slow,, remember the sharp edges on the steels face you,, and keep an eye out for that spacer/washer it likes to stick to the hub in back,, other than that its a slam dunk,, the puller shaft should point the same way as when you removed it initially ,, if not,, you know that washer/spacer is hiding out somewhere! LOL good luck...
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" When in Doubt, There is no Doubt !"
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ZXLNT
Needs a job
Kawpuke Extraordinare
Posts: 2853
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posted March 30, 2007 12:16 PM
While your in there take a look at the actuator arm where it grabs the puller shaft. It may be worn
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buddy
Expert Class
Posts: 335
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posted March 30, 2007 12:41 PM
I'm curious about the impact wrench and breaking the hub nut loose? I always just take the plates out without the need to remove the hub unless a steel is warped so bad it won't come out.
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