Chain off - no clutch.

[Mr Scruff]

Hi all,

Chain came off on Friday - most annoying as was booked in to have it replaced at the weekend! thankfully the wheel didn't lock up and I stayed on. SV 650S curvey.

However, I'm a little concerned about the damage that's been done. I've got a mechanic friend coming over later in the week but could do with some swatting up.

Basically the chain jumped on the front sprocket. I've taken the cover off and it's taken a chunk out of the alternator cover and cut the wires too. I've ordered a replacement cover though and hopefully all should be well there.

I'm more worried about the clutch. There's no resistance at all. I can see the cable running to the lifter arm but from there there's nothing else.

I've been looking at this thread http://forums.sv650.org/showthread.php?t=126381 - the lifter arm seem to just streach the spring. Parts 3 and 4 in that pic are very loose.

Any thoughts as to what might have happened? Is there some sort of pushrod that has been removed/destroyed as the chain jumped forward and took out the alternator cover?

Any assistance much appreciated!

[Alpinestarhero]

Is the worm-drive there? I.e. the little rod that pokes into the engine when you operate the clutch lever...?

[vardypeeps]

Sounds like the push rod that goes inside/behind parts 3 and 4 on the picture has been broken away and lost.

Basically their should be a rod that goes into your engine behind that part which activates your clutch etc. Have a check for that.

[Mr Scruff]

Thanks for the quick replies!

Nope, there's nothing behind parts 3 & 4. I guess I need to source this too. If I call my local dealers and ask for the worm drive/push rod will they know what I'm taking about?

I'm not mechanically minded (least not with bikes) so you can imagine how confused I was!

Because I can't move the bike at the moment I need to wait for my mate to be able to come round and check it out but If I know there are pieces missing I'd like to get a head start on them.

[Alpinestarhero]

Yea, if you ask for the clutch worm-drive they should know. I gues it would have got destroyed when the chain came off the sprocket; they are very close together

[vardypeeps]

Beat me to it :)

[Mr Scruff]

Ok, being dumb again. Local dealer is asking £42 for it, this sound right??

[Stu]

No that sounds like the worm drive
The push rod should only be£8 or £14
Depends what's broken? worm drive? or push rod?

[ophic]

commiserations, mine did this too at 90-odd mph in the outside lane of a motorway. I hadn't adjusted it because it was going for its service very soon. Moral of story - never put off chain maintenance!

[Mr Scruff]

No that sounds like the worm drive
The push rod should only be£8 or £14
Depends what's broken? worm drive? or push rod?

Well, feeling behind the lifter arm there's nothing there at all; no link into the clutch so the whole lot is missing?

I'll take another look when I get home, unfortunately I don't really know what I'm looking for. Might just have to wait for someone who knows what they're doing.

[AndyBrad]

theres a little metal bar that sits behind the worm drive. you dont need the parts 3 and 4. take them off (2 bolts top and bottom) and theres a hole into the casing. this is where the rod goes. It then presses up against the back of the worm drive. You can bet this is missing and or sheared off. a new one is about 9 quid.

[AndyBrad]

oh forgot. its really easy to fix :) it just slides in and then you adjust the clutch.

[Mr Scruff]

oh forgot. its really easy to fix :) it just slides in and then you adjust the clutch.

:)

Thanks very much....

You'll be pleased to know I have at least tracked down the clutch adjustment guide on here! Will make some more calls.

[flymo]

remove the front sprocket cover, pull back and take a photo to post on here. we can see everything we need then.

[Mr Scruff]

remove the front sprocket cover, pull back and take a photo to post on here. we can see everything we need then.

Sprocket cover is off, will take a snap when I get home...

Though parts for my (broken) car have also just arrived so I might have to get that fixed first! :D

[flymo]

Sprocket cover is off, will take a snap when I get home...

Though parts for my (broken) car have also just arrived so I might have to get that fixed first! :D

Try and include a photo of the inside of the cover also as that may be damaged and holds the clutch worm drive

[Mr Scruff]

Ok, so this doesn't look too good!

http://i186.photobucket.com/albums/x220/garnerr2/SL380617.jpg

That's looking back to front

http://i186.photobucket.com/albums/x220/garnerr2/SL380620.jpg

Can see where the chain took out some of the wiring for the alternator

http://i186.photobucket.com/albums/x220/garnerr2/SL380621.jpg

Sorry, poor photo but that's very snapped off!

http://i186.photobucket.com/albums/x220/garnerr2/SL380622.jpg

Back of the clutch bracket

http://i186.photobucket.com/albums/x220/garnerr2/SL380624.jpg

Guess this is where the bar is meant to come out of the worm drive?

[pencil shavings]

dont panic, help is on the way in the from of my experiance of this same thing. moral of the story, look after your chain!! let me find the thread, 1 sec

[pencil shavings]

http://forums.sv650.org/showthread.php?t=117517&page=3

Hope that helps you some, I know its a pointy, but I guess its mostly similar.

Hopfully you will be able to repair it rather than shelling out for a new magnito as well.

[flymo]

http://i186.photobucket.com/albums/x220/garnerr2/SL380624.jpg

Guess this is where the bar is meant to come out of the worm drive?

The bar doesnt connect to it, they are seperate. That worm drive thing you are holding there rotates when you pull the clutch lever and simply pushes the bar into the engine pushing the clutch plates apart on the other side. The bar looks to be snapped and will need replacing.

The worm drive thing looks ok although the photos arent that clear. What about the inside of the cover? There are normally two lugs that the worm drive fastens to, are they missing also? If so you'll prob need a new sprocket cover.

The part of the wiring loom will need taking out and repairing too.

[Mr Scruff]

Ok, quick update.

I've taken apart the the worm drive, removed the remains of the old push rod and manage to assemble it all correctly again. Least I think so, at the moment I'm still awaiting the replacement magneto cover and my auto-electrician mate to repair that part of the loom.

Flymo, I've taken a look at the sprocket cover. I don't have a photo I'm afraid, but there aren't any lugs onto which the worm drive fastens, nor is there any sign of anything that's broken. Does the curvy definitely have this part? The worm drive mechanism fastens securely to the magneto cover.

Fingers crossed, on the way to getting things sorted.

[flymo]

I think you're right, looks like it has a little support bracket.

[yorkie_chris]

Worm drive is attached to magneto cover. Front sprocket cover is ornamental.

[Mr Scruff]

Next update.

Replace magneto and magneto housing (magneto loom was in too much of a mess to try and repair).

Everything is now in place but there's a steady drip of oil from where the push-rod goes into the engine. Is there some sort of cover/gasket that has gone astray or is it a case of just adjusting the push-rod? Was wondering whether it's just going too far in....