[Pariah]

Hey guys, just removed clutch cover and while I was holding the linkage to remove the clutch cable suddenly I felt a huge tension release. I finished unbolting the cover and slid it off only to reveal a weird gear type bolt sticking out from the center of the clutch assembly, it just kind of dangles there.... I am getting a new cover tomorrow but I wanted to tear it down to see what I was getting into. When I tried to put the bent cover back on I could never really get that tension back in the linkage. Granted I didnt fully install it but I am sure that the gears were meshing. DId I do something wrong? Hope I explained this good enough, any help is appreciated. Oh, and it's an 04 R1.

 

[argibson]

difficult to explain, but pm if you want me to walk you through it on the phone. had a terrible time with this until i figured it out.

 

[bryan niles]

Hey guys, just removed clutch cover and while I was holding the linkage to remove the clutch cable suddenly I felt a huge tension release. I finished unbolting the cover and slid it off only to reveal a weird gear type bolt sticking out from the center of the clutch assembly, it just kind of dangles there.... I am getting a new cover tomorrow but I wanted to tear it down to see what I was getting into. When I tried to put the bent cover back on I could never really get that tension back in the linkage. Granted I didnt fully install it but I am sure that the gears were meshing. DId I do something wrong? Hope I explained this good enough, any help is appreciated. Oh, and it's an 04 R1.

that weird gear like assembly is what the rod actuates to operate the clutch. You will have to line it up with the rod in the cover witch has a gear on it that meshes with the gear like rod. The fun is lineing it up and getting it to the proper setting. Nothing is wrong.:hellobye

 

[Pariah]

aw crap I didnt even think about that. ugh.... I think I am screwed. Prolly gonna have to trailer it in and make the walk of shame LOL.

 

[Anubis]

difficult to explain, but pm if you want me to walk you through it on the phone. had a terrible time with this until i figured it out.

:iamwithst

PM me if ya want as well. Much easier to explain by phone.

 

[bryan niles]

aw crap I didnt even think about that. ugh.... I think I am screwed. Prolly gonna have to trailer it in and make the walk of shame LOL.

It is not that hard you just have to have a lttle bit of patients and you will get it. If you have a friend that is a tech have him help you and pay him with some food and beer. once you see how it is done yo will be able to do it yourself.:hellobye

 

[crazyclimbr]

Try a large magnet when you are going to align them. Put the magnet on the outside of the cover where the shaft needs to go. They have these big magnets @ Harbor Freight type of stores that have 100 lbs pulling power. Use some thread to hold the shaft in place (it helps when you have a buddy) and then as you put the cover in place the magnet can guide the shaft as you pull the thread.

 

[Pariah]

Great info by phone guys.... after the cover arrives tomorrow morning I will try and put it to good use. Wish me luck...

 

[Pariah]

Big thanks you guys... it really went smoothly. I think had I not gotten in touch with you by phone I would prolly never have gotten it back together.

 

[argibson]

u r welcome! BTW, did my advice on dropping the arm off the clutch cover gear help or did you get it some other way?

 

[BooBooSS]

Forum to the rescue :fact

 

[Anubis]

Big thanks you guys... it really went smoothly. I think had I not gotten in touch with you by phone I would prolly never have gotten it back together.

No prob. :thumbup

 

[Pariah]

argibson- Yes indeed it did.... you had your rights/lefts confused but that was no big deal, it went together really smoothly. Only snag I hit was that the new cover didnt have a seal or bearing pressed into it and the parts guy didnt think to order them with the cover. I was really pissed seeing as how I paid $60 shipping to have it next day saturday delivery so I could ride this weekend, I would consider that a major oversight. All was well though I just had to drive across town to another dealer who happened to have them in stock. Pressing the bearing in was kinda tricky too just using hand tools but we managed.

 

[argibson]

Good to hear. If you have yamabond, or something similar, you can usually re-use the gasket on the clutch cover...but seeing as how much of a pain getting it on and off is, it would really suck if it leaked from a bad gasket after getting everything back together. Glad you found one in stock.
Cheers,

 

[BooBooSS]

It's a little tricky the first time but if you push the bolt into the case cover (with the gasket in place) and through the gasket first... being careful not to pinch the gasket anywhere the bolts go through you can re-use it TONS of times... Since we drag race I've went through at least 30 sets of clutches this year... :lol

Maybe we'll do a video on changing this out sometime.... :lol