Disaster - clutch push rod has snapped!!!

[cagiva996]

might have one you can have-will check part numbers first

[Kayla]

We've got one of these

http://www.machinemart.co.uk/shop/produ ... sion-jacks" onclick="window.open(this.href);return false;

it's well worth the money

[cagiva996]

had a look-cant find the bloody thing-sorry!

[plodder]

If you can't magnet the rod out, take off the clutch pressure plate [item 6]. The release bearing [item 9] can be taken out of the hub and directly behind that is the pushrod (there may be a ball bearing (at least there is on 1000s but maybe not on 600s/400s). Poke it through and you'll be able to get it out the broken end. I don't think you have to take any plates or steels out but it's been a while since I has one of these apart. It's not a problem job though.

As for sprocket nuts, lock it in gear put the back brake on and get a big lever on it anticlockwise. Then get the air impact gun on it and repeat. Penetrating oil and heat on the nut will also help.

If it still won't go then you can drill the nut close to the shaft threads to release the thread pressure (it will also get some penetrating oil in there if close enough). Be careful not to knacker th threads... you only need to remove the pressure, not drill off the thread.

[smemly]

when i finished putting the engine in my hybrid i started it for the first time with the sprocket cover off and the oil pressure was enough to push the clutch rod & the ball bearing out.

Thankfully i managed to relocate everything with no damage done, can't definately say it'll work and wouldn't want to be responsible for your engine destroying itself but i believe the tube that the rod sits in is sealed through the engine to the clutch side.

[sparkles]

Nick

Drain oil and remove clutch cover and take of out clutch springs and pressure plate. Now remove the circular bit in the centre of the clutch basket, no need to remove clutch plates. be carfull while taking it out for there is a ball bearing behind remove this with magnet. now with a tent peg push rod out from this end.... and vallar the push rod reapears the other end. If you need a push rod I have one spare at home... just call it a helping hand for £10 posted

Pm me if in need.... The only way i know this works is for it happened to me also replace the seal afterwards for peace of mind.

Chris

To take clutch cover off you dont have to drain oil out

The way i do it it put a axel stand under side of frame by the clutch cover and use the side stand to support the otherside so that bike is leaning over further then it normally would with front wheel off the ground
You have to be carefull the side stand dont fold up so best get some rope or something and tie it to something on the bike so that is in the down postion all the time

[Motorcycle Solutions]

You drain the oil to make sure no metal fragments got into oil or you are in big trouble... ? I only use a axle stand to change clutches or if you know that there is no metal in the oil, you can syth the oil to check for metal fragments and if oil is clean, you can reuse if it is not to old...

[Motorcycle Solutions]

Nick

rod posted......
with you tommorrow......


if need part numbers i have um all..

[Evilchicken0]

In this case I'd drain the oil. If it's a road bike then you can replace with semi-syth ... so it's only about £20 ... plus you'll have changed the oil which is a plus

[nick]

Thanks for all the help with this one guys. I've done just about everything to try and shift the sprocket nut but no joy, so i've got myself an impact wrench in the hope that'll undo the mo-fo

Chris - ta for the push rod, took your advice on the removal trick. Thought about not draining the oil, but it probably needed it, plus it gave me a chance to check the clutch plates and springs.

So, fingers crossed