stevew
Parking Attendant
Posts: 12
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posted June 22, 2009 11:21 AM
Sprocket Change and Clutch Slave Cylinder
I'm about to change the countershaft sprocket on my '08 ZX-14 to the 16t OEM variety together with a 43t or 42t rear depending upon the fit with the stock chain (I’m running the stock wheelbase at present, but am a big boy weighing in at 270lbs). The rear sprocket is no problem, but this will be my first attempt at changing the countershaft sprocket. I have done a fair amount of searching/reading within the forums and reading the service manual and am well aware of the difficulty with the nut holding on the front sprocket. Nevertheless, with the hints on this forum about removing this nut, I think I'm well prepared to tackle that problem. I guess we’ll see. ;-)
The part that I am not sure about, based upon my research reading the various forum posts, is the removal of the front sprocket cover, specifically as it related to the clutch slave cylinder mounted to the cover. According to the service manual, it instructs you to completely remove the clutch slave cylinder which I would like to avoid for obvious reasons unless absolutely necessary. I want to minimize or eliminate any servicing of the clutch (bleeding the system, etc.) during the process of replacing the countershaft sprocket, and I have read conflicting posts on this forum on how to do this. Completely removing the slave cylinder seems overkill.
From what I understand, after I remove the lower fairing, I remove the four bolts holding on the sprocket cover, the speed sensor, and the long upper left clutch slave cylinder bolt which fastens to the engine. I understand that I do not need to remove the remaining two slave cylinder bolts which merely faster to the cover itself. So far so good.
Once the sprocket cover pops off (or is pried off?) What can I expect? Will I need to deal with leaking hydraulic fluid or need to be aware of anything related to the clutch slave cylinder assembly such as any additional internal clutch pieces as I move the cover out of the way as long as the slave cylinder is still attached to the sprocket cover by the remaining two bolts? In one post, it was indicated that I should make sure NOT to touch the clutch lever at this point in time. Another post seemed to indicate that I should pull the clutch level all the way in, using tape to hold the lever in this position. Since this is the exact opposite advice, I'm confused as to what to do. I'm hoping that I can do this in such a way as to avoid any clutch system maintenance. What is the correct way to accomplish this?
Is there anything I need to be aware of when I button the cover back up with respect to the clutch slave cylinder? Does the cover just pop back on or do I need to be aware of aligning anything in particular with respect to the clutch slave cylinder?
Any other words of advice aside from the infamous damn nut?
Thanks in advance.
  
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Revs
Parking Attendant
Posts: 5
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posted June 22, 2009 12:46 PM
Stevew,
Do exactly what you outlined in paragraph 3. Nothing will fall out. The cover comes out fairly easy as long as you got all the bolts out. Once the cover is out hold it suspended to the front by a bungee cord. Bend the locking tab back that is behind sprocket nut. With a friend stepping on the rear brake with the tranny in neutral spin the sprocket nut off with an oiled impact gun and a 27mm deep well socket. Mine came off easy with no locktite detected (07). Move rear wheel forward to loosen chain up front. You might suspend the back prior to this. Install 16t sprocket and reverse the process. Torque sprocket at 94 ft/lbs and dont forget to bend tab washer to lock the nut at a different location if the same washer is used. Cover will go easily back on if the bolts holes are aligned. Put some removeable locktite on cleaned bolts and holes that had them. Nothing else to do or adjust up front
Revs.
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Revs
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Revs
Parking Attendant
Posts: 5
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posted June 22, 2009 12:53 PM
SteveW
I forgot to mention the chain guard that is around the sprocket needs to be removed (3 bolts locktited in) to make countershaft sprocket and chain removal and installation easier.
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Revs
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stevew
Parking Attendant
Posts: 12
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posted June 22, 2009 02:03 PM
Hi Revs,
Thanks alot for your response.
So just to clarify, I don't need to worry about the clutch lever being engaged while I am working on this, correct? I'll just leave it alone (clutch disengaged). Seems very straightforward. I'll give it a shot as soon as my 27mm deep well socket arrives in the next day or so.
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Douglas Home
Zone Head
Posts: 710
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posted June 22, 2009 02:23 PM
Hi , when your clutch slave cylinder is off , make sure you dont touch the clutch lever.
I've on 07 14 and it came off easy no impact gun ! seems to be pot luck!
If you have feral kids , jamb something inbetween theclutch lever and handlebar!
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Doug Mackay Australia
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stevew
Parking Attendant
Posts: 12
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posted June 22, 2009 04:07 PM
OK, got it! Thanks for all your help. Hopefully my sprocket nut comes of relatively easy as well. Fingers crossed. ;-)
Thanks again.
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AcadianaZX
Advertiser
Posts: 530
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posted June 23, 2009 08:09 AM
quote:
Hi Revs,
Thanks alot for your response.
So just to clarify, I don't need to worry about the clutch lever being engaged while I am working on this, correct? I'll just leave it alone (clutch disengaged). Seems very straightforward. I'll give it a shot as soon as my 27mm deep well socket arrives in the next day or so.
I had to pull in the clutch lever and tie it with a wire tie. Doing that holds the cylinder inside the slave before disasembly. So when you put it back together you won't have to fight with having to get the cylinder back in the slave or any leaking fluid. I believe you can download the ZX14 manual here on the forum.
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eklipse636
Needs a life
ZX-14
Posts: 6046
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posted June 23, 2009 09:04 AM
Wierd... I've NEVER heard anyone say hold the clutch lever in... Nothing leaks out when you don't touch the lever.
My advice, after the sprocket cover is off, DONT touch the lever. I did mine that way and it worked perfect!
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Best: 60ft 1.351 1/8 5.68 mph 123.98 1/4
8.89 mph 151.32
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AcadianaZX
Advertiser
Posts: 530
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posted June 23, 2009 10:58 AM
quote:
Wierd... I've NEVER heard anyone say hold the clutch lever in... Nothing leaks out when you don't touch the lever.
My advice, after the sprocket cover is off, DONT touch the lever. I did mine that way and it worked perfect!
My advice was to really download the manual. I wasn't saying anyone was wrong, just my 2 cents. My clutch slave cylinder creeped out the first time I did mine. Was hard to push back in. Second time I read the procedure in the manual. The manual download is at the top of this forum.
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14nooby
Zone Head
Posts: 987
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posted June 23, 2009 04:42 PM
Make sure you use a 6pt socket and not a 12 point. The use of an impact gun will chew up the nut and probably won't be strong enough. I used a 4 ft breaker bar with a 2x4 in the rear tire to keep the tire from spinning. I literally broke the 2x4 and had to get another one. If anyone tells you it came off easy its because at some point that front socket was taken off. Let us know when you are done.
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Douglas Home
Zone Head
Posts: 710
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posted June 23, 2009 05:04 PM
My 07 came off easy and I bought it new! I'm just lucky I guess!
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Doug Mackay Australia
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Shane661
Needs a life
Posts: 11494
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posted June 23, 2009 05:07 PM
quote:
Make sure you use a 6pt socket and not a 12 point. The use of an impact gun will chew up the nut and probably won't be strong enough. I used a 4 ft breaker bar with a 2x4 in the rear tire to keep the tire from spinning. I literally broke the 2x4 and had to get another one. If anyone tells you it came off easy its because at some point that front socket was taken off. Let us know when you are done.
A good impact does it without leaving any marks on the nut. It also won't require any boards.
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eklipse636
Needs a life
ZX-14
Posts: 6046
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posted June 23, 2009 07:18 PM
I used a campbell hausfield air impact, and the nut laughed and shot me a bird! Had to get 4' pipe and about took the bike off the stands
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Best: 60ft 1.351 1/8 5.68 mph 123.98 1/4
8.89 mph 151.32
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TooHype
Expert Class
Go Hard or Go Home !!
Posts: 427
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posted June 24, 2009 10:51 AM
quote:
My 07 came off easy and I bought it new! I'm just lucky I guess!
 ...+1
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Go Hard or Go Home !!....2007 Diablo Black ZX-14, BMC Race Filter, Brock's Alien Head, Brock's Radial Mount Strap, PClll with Custom Map, Flies removed, Muzzy fan, Muzzy lowering links, Muzzy Fender Eliminator, 16/41, Speedohealer, Stretched 6", Lowered 3" IN GOD I TRUST !......If You’re a Hater….KILLYASELF !!
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TooHype
Expert Class
Go Hard or Go Home !!
Posts: 427
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posted June 24, 2009 10:53 AM
A good impact does it without leaving any marks on the nut. It also won't require any boards.
 ......+1
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Go Hard or Go Home !!....2007 Diablo Black ZX-14, BMC Race Filter, Brock's Alien Head, Brock's Radial Mount Strap, PClll with Custom Map, Flies removed, Muzzy fan, Muzzy lowering links, Muzzy Fender Eliminator, 16/41, Speedohealer, Stretched 6", Lowered 3" IN GOD I TRUST !......If You’re a Hater….KILLYASELF !!
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