clutch problem

[Machinegunner20]

Ok see what you think about this, Yesterday while changing out the clutch

1. Placed bike in 1st gear to remove clutch boss nut. Back tire kept spinning so I applied breaks while sitting on bike. After wrestling to get nut off it finally comes off with breaker bar. During the prossess I heard metal grind kinda sounded like chain hopped the sprocket from all pressure being applied and tire not moving. (My GUESS)

2. Everthing is going well with assembly I get to the springs and bolts. Went out bought a torque wrench just for these little bastards. Book calls for 9. somthing lbs. Well in the middle of torqing, the wrench never clicks and the bolt snaped into pressure plate never really felt any torque on the nut either so I dont know why the wrench would click.

3. Got all mad cussed up a storm, contimplated lighting bike on fire in the middle of yard.

4. put bike in Neutral to roll back into apartment.

5. Bike wont go back into gear now?? Not 1st or 2nd could this have to do with that noise I heard in the 1st question?

6. Went to Lowes today purchased a laser drill press to help in the extraction of the nut from pressure plate. Got it out with minimal effort. Ordered new bolt and extras from velocity should be in next week.

Do you have any idea why bike wont go into gear, I can hear the gears click but I can still push bike away as if its in Neutral. Also how in the world do you torque those bolts with a torque wrench and not break them. Maybe my torque wrench is a Piece of crap? Who knows but any info in this situation would help thanks. Send me a private message so you dont have to make it a fix it forum.

[mccutch2u]

probably screwed one of the shift forks or something what kind of bike is it

[Turbo storm]

He's got Kenny and matts old racing R1

The bolts at 9 ft pounds seems like alot for an M6 bolt. Make sure it's not 9 inch pounds. I've got small torque wrenchs that may work better for that application.

I can't see bending a shift fork unless you are trying to shift. He simply used the rear brake while in gear to hold the basket. The shift forks should have had no pressure on them.

If you are just replacing the clutch fibers and steels, why were you taking off the clutch basket?

[Scootimus]

I was going to say the same thing about the possibility of it being in/lbs. seen it happen before.

[slosir]

those bolts do torque to in. lbs., usually about 7-10 in.lbs. did i mention they were in.lbs.?

[Turbo storm]

those bolts do torque to in. lbs., usually about 7-10 in.lbs. did i mention they were in.lbs.?

Any ideas on why he is having trouble with the gear problem?

[mccutch2u]

clutch spring bolts are 7.2ft lbs on that

[Professor Fate]

Any ideas on why he is having trouble with the gear problem?
Plates are not seated correctly, no lever free play,ect ect.... Would need to see to be sure.

[mccutch2u]

put the bike on a rear stand and pull the clutch cover with the bike in what should be first gear spin the rear tire to see if both the inner and outer hubs are spinning if so then it may be in the cases if not then re-examine the clutch if only the outer spins

[Turbo storm]

put the bike on a rear stand and pull the clutch cover with the bike in what should be first gear spin the rear tire to see if both the inner and outer hubs are spinning if so then it may be in the cases if not then re-examine the clutch if only the outer spins

Good idea...sounds like you've worked on an R1 before. just kidding

[Professor Fate]

Sounds like he needs an outside on da sucker. Might over looked something. Be happy 2...:chin:

[mccutch2u]

i have i put a graves clutch kit in mine what a mistake..........stock is the way to go


plus I have the manual on my pc

[Machinegunner20]

No its not in.lbs its 7.2 ft lbs I had to take the clutch boss off bc there are two plates, a fiber and a metal then a piece of piano wire seats into the clutch boss holding those two plates up against the pressure plate tightly this is all before stacking the rest of the plates. (If piano wire isn't installed correctly it can break off and end up in engine so I took boss off, it would have been nearly impossible to install the wire while still on the bike.

[mccutch2u]

you really don't even need that wire with the graves kit they do away with that wire and the smaller fiber in the back replacing it with a standard fiber the downside is that you will occasionally get some chatter in the clutch

but really not a big deal just annoying

[Machinegunner20]

So I tried spinning the back tire like you said. Clutch boss is still off until I get my hands on that new bolt. Well in the process of spinning back tire only the shaft is turning, didn't know what you meant by hubs? Still nothing when I tried to shift while back tire was in rotation. No problem clicking through gears up and down just acts as its in neutral while clicking through gears.

[Turbo storm]

David,

If the clutch fibers and steels are out, the gear selection will not matter.

as you turn the back wheel, the splined hub in the middle of the clutch assembly should be turning with the wheel (this attaches to the sprocket on the other side). The clutch basket is what is attached to the engine. When you pop it in gear, it will not turn by hand. Pop it in neutral, and it will spin either way. If you need anymore help, give me a call. You got my #'s
Dan da man

[slosir]

No its not in.lbs its 7.2 ft lbs I had to take the clutch boss off bc there are two plates, a fiber and a metal then a piece of piano wire seats into the clutch boss holding those two plates up against the pressure plate tightly this is all before stacking the rest of the plates. (If piano wire isn't installed correctly it can break off and end up in engine so I took boss off, it would have been nearly impossible to install the wire while still on the bike.
my bad, but i will say that most ft.lb torque wrenches that go that low are not very accurate. multiply ft.lb value by 12 to get in.lb. value(7.2x12=86.4in.lbs.)

[Machinegunner20]

So velocity called today and the bolts(I ordered xtra) are in so when I get off work here in the morning I'm gonna pick em up and get started. Thanks, you answered what my next question would have been, "if I could use a in. lbs torque wrench". I may have one sitting around the house somewhere. Thanks for everyones help on my 1st clutch job and hopefully it will be up and running by 2morrow nite.

[DK]

Did you ever check and see that the oil pump chain was still intact ?
(Older R-1's were this way a few years back, would imagine yours is the same way)

((It may not shift into gear until you hold the clutch basket and prevent it from freewheeling if all of the plates are removed. Spin counter shaft by hand and retain the main shaft with your other hand while shifting. This should allow it to engage the gear))

If that does not work, than just hit me up PM.

[Machinegunner20]

I seen the chain you were talking about, I removed the clutch basket to take a ganderd and it was intact. The problem was where I asked someone if it should go in gear with the clutch removed and they said, YES. So I was confused on why it wasent going into gear when the clutch was removed in all acutallity I found out that if the clutch is removed the back tire will just keep spinning like its in neutral anyways.

[dizzyg44]

and those bolts by the way are usually pretty weak bolts and break quite alot when trying to reuse them. If they are old look at the head end of the bolt, it's not uncommon to see they are stretched. Luckily they are readily available at lowe's\home depot, at least mine are. I never ever reuse them anymore.

On the falco last time my clutch was slipping like mad my clutch looked perfect, as usual looked at the bolts small thin spot just under the head of each bolt from stretch.

each bolt was about 2 to 3 mm longer than they were supposed to be, swap bolts, clutch was perfect.

[DK]

I seen the chain you were talking about, I removed the clutch basket to take a ganderd and it was intact. The problem was where I asked someone if it should go in gear with the clutch removed and they said, YES. So I was confused on why it wasent going into gear when the clutch was removed in all acutallity I found out that if the clutch is removed the back tire will just keep spinning like its in neutral anyways.


Well, let me know if it starts working properly. Just retain the mainshaft in your hand putting tension on it as the counter shaft is spinning. SHould shift fine. I would pop the oil pan off your bike and ensure that there is no fiber material present in the bottom of the pan. The oil pump will pick that stuff up again and wear stuff out prematurely id not cleaned properly. It's bad news.

Get it together and let us know how it went.