Help a DIY Numpty: clutch release mechanism

[JustATrick]

I've just tried to change the chain and sprockets on my K1 SV650. All went pretty well until it came to putting the clutch release mechanism back together and getting it adjusted. I had a few doubts about which way the release bit fitted onto the worm-gear, and which end of the push-rod should point towards the engine, but managed to put it back together so that it looked about right. I adjusted it as I'd done before, using the gospel according to Sid Squid (except that I didn't touch the cable adjuster at the handlebar end). Somehow, it didn't feel right, but I put the rest together and got ready to try it out. Unfortunately the engine stalls as soon as I select first gear with the clutch in.

I tried to adjust it again (it's 11:30pm by now), but without making any difference. So I pulled the release mechanism off to see if I could put it together any other way. I don't think I can: if I reverse the release mechanism bit on the worm-gear it ends up at the wrong angle for the mounting holes. I've looked closely at the picture in my manual, and I think it shows it the same way as I have it. There's a little tab that protrudes from the worm-gear 'bearing' which is facing towards me.

At this point I give myself a real fright: I pull the push-rod out to have a look and see if I could have it the wrong way around. Oil starts pouring out of the engine, and I lose about 3 tablespoons before I jam the rod back in the hole. First thought: I've put it back so badly that I've damaged a seal and ruined it :smt089. After a little while I calm down and remember that last time I pulled out the push-rod the bike was vertical, on the Abba stand. This time it's on the side stand. Is it just the angle that means I lose oil out of that hole? Or have I damaged the bike?

I decided to give up for the night and give my neighbours a rest from the banging and swearing.

Any advice on how I can be sure I've got everything back together okay? I know it's hard to describe, but all attempts appreciated. I'll give it another go tomorrow in the light and with a better attitude. (I'm going to have to take some time off work: family emergency? ;)). I couldn't have picked a worse time to mess this up :smt100: I need the bike tomorrow night to head up to Donington Park for the MotoGP, and then I've got my first trackday booked at Darley Moor on Monday...

[Bibio]

sidestand switch.

[rictus01]

as above you sure it's the clutch ? you say stalled, do you mean cut out ? it should have pulled a bit first?, clutch cutout or sidestand switch?

Anna done an easy to follow guide to adjustment (http://forums.sv650.org/showthread.php?t=126381) with pictures showing the adjuster in place.

HTH

Cheers Mark.

[Spanner Man]

God morning.

Firstly, does the clutch lever feel the same as before when you pull it? If it does the chances are you have got the release mechanism together correctly.

As Rictus says your bike would lurch forward if the clutch isn't disengaging properly. So, if your bike is cutting out immediately it's more likely the problem is the interlock circuit that prevents the bike being ridden with the sidestand down.
As suggested check the sidestand switch, although you shouldn't have disturbed it, you never know.
Also, check the clutch lever switch on the lever mount itself, as it's possible that it's not working properly due to the cable being slack when you had the release mechanism off.
Give me a call if you need any advice.


Cheers.

[JustATrick]

sidestand switch.

I did promise I was a numpty, but didn't expect it to be this bad.

You, sir, are a genius. As are rictus and spanner man. Because I was worried, I was 'testing' it as soon as possible: before swinging my leg over the bike. It was still on the sidestand... I can't find a smiley for very embarrassed and very relieved...

It works. The adjustment is out, but I'm sure I can fix that this morning. One last thing, I realised I forgot to grease the ends of the push-rod, so want to do that before the final adjustment. Should I expect an oil leak when I remove the push-rod? Should having the bike vertical make a difference? (I remembered that I did actually have the bike on the side-stand when I removed the push-rod the time it didn't leak...)

Thanks to all for your time - I definitely owe some beers. I'll have to see if I can make a brief appearance at Ar09 to pay up...

[Spanner Man]

HE he he:D At least it's sorted, that's the main thing.


Cheers.

[Bibio]

we,v all done it...

if you remove the pushrod and the oil level is at the other end of the hole for the pushrod, then yes oil will come out.. as long as its not massive amounts that come out dont worry about it. you can always top the oil up afterwords...

[JustATrick]

Thanks again guys - it's all back together and adjusted nicely. I had a quick half hour blast, and all seems fine: really smooth gear changes with the new chain and sprockets.

Right, off to work for a few hours then MotoGP here I come...