salsa1
Needs a life
Posts: 5971
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posted June 04, 2006 04:45 PM
 Edited By: salsa1 on 4 Jun 2006 17:55
Changing clutch messed up??? need Help..
Just changed out all the steels and fibers on my 04 ZX-10R ; finished putting the clutch cover but I discovered have no tension on the clutch cable?.. Its limp ?? only thing I can say I did different was put .025" washers under each spring. What did I do wrong? I wonder if the clutch spring plate that goes in before ya put the springs in needs to go in differently? not sure if I understood the maintenance manual here.
also... I tightened the springs down fairly tight without a torque wrench.. is it possible too tight could cause the clutch to freeze up somehow?
I 'm lost any ideas?.......
Any insight or experience is sure welcome and very much appreciated.
Thanks,
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Salsa1
  
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kre racing
Novice Class
Posts: 38
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posted June 04, 2006 10:32 PM
reinstall the cable paw into the cover by rotating it clockwise and droping it in.
if its not engaged with the puller rod you will have a limp lever
let us know how it works out'
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mdzx10r
Novice Class
Posts: 50
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posted June 05, 2006 12:35 AM
Outside hub not seated down properly? It onlt goes on in a couple positions.
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salsa1
Needs a life
Posts: 5971
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posted June 05, 2006 05:14 AM
Edited By: salsa1 on 5 Jun 2006 07:14
Will open today and see what I can determine...cable paw should be in as it engages when rotated in and locks to where cannot be pulled back up.
If tightening the springs down is not a likely problem then hopefully the hub as per book need to go in a certain way... It seemed like it went in ok to me.. not sure now..
the suspense is not thrilling.. just don't like playing discovery mechanic with my baby...hate set backs on account of ignorance.. . read some guy payed dealer $900.00 for clutch change..I guess I see no reason to pay that much....
Thanks!
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Salsa1
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salsa1
Needs a life
Posts: 5971
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posted June 05, 2006 10:01 AM
Edited By: salsa1 on 5 Jun 2006 11:17
Opened back up and indeed the spring plate or Hub as some call it was not perfectly in place. close but no cigar.. jesse I hate when that happens...
Now she works ;...good grip from clutch except shifting is more klunky than before; hard time getting neutral when stopped with engine running. will adjust cables more when I get home but I have a feeling the 0.25" washers I put under every spring is creating this effect..the clutch pull is somewhat harder too but I can live with that if I need to ..
should help put more pressure on clutch and preserve clutch bit more and give better 1/4 mile launches I hope. can always remove washers later if I want to.
somedays I wish I knew everything...lol.
Glad she is working for now but will see if can achieve smother shifting and easier neutral find... any Ideas? I also get a chattering noise when I pull the clutch in all the way at the clutch lever?
Thanks!
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Salsa1
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mdzx10r
Novice Class
Posts: 50
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posted June 06, 2006 12:39 AM
I don't remember ever having a chatter problem , but most likely with everything being new it is on the tall side for stack height and just riding it a little or a few aggressive launches will fix the problem of trouble finding nuetral. Your plates are most likely still dragging a little with clutch pulled in could be causing the chattering too.
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salsa1
Needs a life
Posts: 5971
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posted June 06, 2006 02:28 AM
Edited By: salsa1 on 6 Jun 2006 05:51
"but most likely with everything being new it is on the tall side for stack height and just riding it a little or a few aggressive launches will fix the problem of trouble finding nuetral. "
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Hope you are correct; I get thoughts the transmission or something else got messed up when I ran the engine with the spring plate not fully flushed against clutch pack. also thought I might need to clean out the so called " pick up " associated with clutch debry as I ran several times while whe was slipping on the streets and the old friction plates were worn quite a bit .
She shifted like butter before.. got to get that back... maybe with all new friction plates the extra .025:" washers under the springs are componding stack height problem temporarily. will have to try a few hard launches to see if that does improve. otherwise I feel inclined to take out the washers back out...
should add : even when the clutch is pulled in with the lever ; I get a slight forward motion from the motorcycle like the clutch is not fully in as it should be. cable adjustment has not been able to correct this so far..bike should be like in neutral with clutch pulled in but not 100% so..
hopefully it is just all new plates and stack height being a bit tall...won't rest well until fixed ....
Salsa1
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Salsa1
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CrotchRocket
Moderator
Bracket Racing with Betsy
Posts: 8038
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posted June 06, 2006 06:53 PM
Glad it works now...Until the clutch is worn in a little you will get the creeping when the clutch lever is pulled in!!!
With the washers/shims you will also find it hard to put the bike into nuetral until the clutch is worn in...
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Jason Miller StreetBike Seminars
*****DragRacers do it better, because they dont cut Corners*****
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