Trackday project K3

[Redmist]

With the parts ready to fit to update the gear change star to hopefully get rid of those pesky false neutrals, I set to in the shed with getting it swapped.

Firstly drain both the coolant and oil, before undoing all the cover bolts including the three that hold on the coolant pump BUT don't remove the pump so as to not need another gasket.

With some leverage the clutch cover will eventually prise off.

Carefully undo the clutch bolts and pull the pressure plate off.

Now realise you don't have a clutch holding tool and finish for the night while you get one, so that you can undo the big nut!

To be continued...

[Red Herring]

Have you not got access to an impact gun? If you leave all the plates in place (you obviously have to remove the pressure plate) then there is usually enough friction in the system for the basket not to spin, especially if you push on the outer plate with your spare hand (tip, put a rolled up rag over the plates first and push on that otherwise you tend to take the skin off you finger tips when the basket does turn a bit!).

[Redmist]

Sadly not, for the price of an adjustable one at £12.99 off ebay I'll get me one of them.

Appreciate the tip tho.

wow Redmist have really enjoyed spending the time reading through and following your progress top job by the way real nice.
I myself have an K3 which im currently riding on the road but she too will eventually be turned solely into a track day bike after this summer i reckon a little winter project for the following summer.

[Redmist]

Do it Dowser, you won't regret it!

In other news I finished up the gear change star swap.

After buying the clutch holding tool I was able to undo the main clutch nut.

Anyway, you need to remember to remove the circlip from the gear change shaft:



Here's where we are now, the full clutch removed:



Block the sump holes to stop anything dropping in there and losing it forever.
Then pull the gear change shaft out, mine only came out a few inches but it was enough:



The star comes off after undoing the screw from the middle of it. A screw driver is necessary to stop it turning whilst you undo it.

Carefully remove it and then unscrew the bolt holding on the arm and remove that too with the spring.

Replace with the new parts and use some locktite when screwing in the new parts.

Clean away all the old gasket.

I had some issue when putting the clutch back in as a whole, eventually I took it all to pieces and put it back in piece by piece and all was well again.

Then it was just putting it all back together again torquing up as required.

Here is the difference between the original and the k5 parts:



Oil is back in but I'll wait for the warmer temperatures before putting the distilled water back in the radiator.

All in all a reasonable simple job, lets hope it does the trick!

[Redmist]

So Cadwell on the 7th of March was bruddy brilliant!

Loads of fun on track and all work over winter SEEMED to be holding out well.

Met up with a fellow Orger, Lawman who was a great challenge to ride around the track with and we had some good dices with the bigger bikes.

So I logged on to the trackday photos website as usual and spotted something a bit worrying!!

Namely this image:



And a close up:



Looks a lot like a coolant leak, either from the drain plug or the gasket around the pump.

I had no idea until I saw these images!!

Needless to say I shall be investigating this weekend.

Any guesses??

[Bibio]

that shot deserves to be framed and hung on the wall in the garage

[Redmist]

Originally Posted by Bibio

that shot deserves to be framed and hung on the wall in the garage

Yup one in a million shot!

So the small object in the photo must be the coolant drain plug, as I seem to be missing mine!

I went back and looked at my gopro footage and it was the 3pm session that it happened in, having no idea it had happened, I did two whole 20 minute sessions with no coolant!

So today I found a replacement bolt and put some water back in.
I also replaced the oil as I guess it had a tough time trying to keep things cool.

The engine must have sustained some damage but all I can do is keep an eye on things and hope it makes it thru the year!

If you didn't notice it loosing power, it's probably o.k.
but, as you say, monitor it carefully.

Hey Redmist - can the clocks just be unplugged without upsetting any of the electronics? I'm thinking about going for the minimal look for trackdays, lighter and cheaper to drop. Did you miss the fairing at Cadwell? Cheers, Jon.