Clutch problems.
 

I have been having some problems for like, 24 hours now. On my way home from work yesterday my clutch shat itself, leaving me a little bit arsefaced until some chaps gave me a bit of a push and i made it home the 20 miles sans clutch.

I then took the mechanism apart and this left me with a broken left hand clutch push rod. ?8 later, I had a new one, fitted it, went off, clutch wouldn't disengage. Poopie. I then got it working and set off to work, then 5 miles down the road clutch won't disengage again. I think it's just going to be a case of setting some more slack on the cable. Anyone have any other ideas?

Re: Clutch issues
 

could the plates be sticking together?

Re: Clutch issues
 

Is the worm gear mechanism all present and accounted for?

Re: Clutch issues
 

Not sure. Although presumably my broken left hand push rod was the problem, and tomorrow when I go to fix the bike I'll slack the clutch off a lot, see how that gets me home. Basically if I screw the mechanism up really tight, the push rod is already engaging the clutch. So I undid the screws about a quarter turn and found what I thought was a happy medium. Fail. If that doesn't fix it, I'll dump a whole bunch of WD40 in both sides and see what happens.

Re: Clutch issues
 

Might as well start from basics...

Rinse then regrease the worm gear, set it so it's just contacting the pushrod when the arms at 90 degrees then take the slack out of the cable.

Re: Clutch issues
 

I am an idiot, so by worm gear do you mean the worm gear on the left hand side of the bike that pushes the pushrod and engages the clutch?

Re: Clutch issues
 

Yes thats the one, its a helical cut inner with ball bearings around it, if it's knackered then that wouldnt help.

You've confused me here though, as pulling the clutch disengages the engine from drivetrain.

Which way round is your problem?

Re: Clutch issues
 

what happens if the ball bearings come out?

Re: Clutch issues
 

It either doesn't work at all or binds up

Re: Clutch issues
 

ah ok time will tell i guess on my gsxr

Re: Clutch issues
 

lol, i've had a ballbearing pop out, found it though. Hmm, I managed to get it to work, although my worm gear, if i screw it all the way into it's little mounts will continuously disengage the engine from the transmission, so I have to have it slightly loose and i'm thinking of getting some washers so it's more of an exact science. Either way, managed to fix it!

Re: Clutch issues
 

Just seen this ...

You haven't actually mentioned adjusting the worm gear itself (just the bolts that hold it to the engine it reads to me).

You are aware the adjustment should be a combination of cable and the little screwdriver slotted thing (and locknut)?

The angle the arm starts off at is imperative to having a correctly functioning clutch. You slacken the cable right off, then adjust the angle with the worm gear screw/locknut arrangement, then adjust the cable to take up the slack ...

Have you got the users manual?

They are a sod to adjust/get just right and if you don't get the start angle right, you are onto a loser straight off ;)

If not you can get an e-version here :)

Its this one you want in particular ... page 2-17 8)

Re: Clutch issues
 

Cheers dude, I'll take a look at it and sort it all properly. For the moment it seems to be working great, no issues at all in a few days.

Re: Clutch issues
 

ARGH I have this manual downloaded! Why did I not see that earlier? I was thinking 'there must be some other way to adjust this', did not realise that (4) on the clutch adjustment page would actually do anything if I turned it. Cheers for setting me straight, other than that, the bike has been pretty good going, new battery, new throttle cable and that's it, really!