Dan's NC30

[iDemonix]

AGH!!! FUCKING STUPID MOTHERFUCKING BOLTS!!!

There's one bolt left in the clutch cover, ONE! And it is rounder than a fucking clock. Soaked it in WD40 again but it's just not giving!!

[iDemonix]

Decided to play some PS3 instead.

Absolutely pissed off beyond belief. Rounded bolts are my living fucking nightmare. Tried putting the 8mm open ended on and hammering a screwdriver in, no joy, can't file it because of where the stupid thing is.

Might just reassemble the stupid piece of shit and take it to a fucking mechanic. Fuck this.

[iDemonix]

A mechanic I know leant me a tool and I removed the bolt, I'm now a little stumped trying to 'unstake' the clutch nut. I can't seem to get a screwdriver in between the black bit and the metal clutch castellated nut, I'm worried I'll break it if I hit it any more... hmmm...

[iDemonix]

Hi-Res Image; http://i.imgur.com/IPDUa.jpg

[iDemonix]

Right, I've swapped the plates and so on, I'm doing the reverse now but the clutch nut is giving me a bit of grief again, I can't get it to tighten to 85NM, I tried and it just made a noise and became loose again, I don't want to risk ruining the thread, so I've done it up as tight as I can using a rag in the cogs and it seems to be ok, but I'm not staking the nut as I didn't unstake it. Anyway this is what it looks like now, can someone confirm this looks fine before I put the pushrod and so on back in?

http://i.imgur.com/MURBO.jpg

Cheers,
Dan

[iDemonix]

I thought it all went well, but my clutch lever is lifeless and has no response, however it was fully adjusted out before, so I'm going to reset the adjusters and see if it feels like a clutch, if not then i've done it wrong which is annoying as I've just rebuilt and topped up with new fucking oil. FML.

[iDemonix]

Nope, there's just no clutch response, I feel like absolute shit and wish I'd never undertook this job. What a ball ache. I've now got to drain the oil - again. Remove the cover - again. And try and suss out what's wrong. I hand on heart wish I'd never ever attempted this.

[iDemonix]

RIGHT. Ignore everything I've put so far.

The spring had come off on the left hand side of the bike, don't ask why. I put it back on and threaded the adjusters through - it feels like a clutch now. So I was about to start it up, but I can't engage neutral.

I'm sorry I've spammed like the last 20 replies or something, but does anyone know why this would happen?

Cheers,
Dan

[CMSMJ1]

you need a beer...

Chill.

Bikes are simple beasts and whatever you have fucked up..is not going to be as fucked as you think.

so, drink some more beer..

No neutral? move the rear wheel and try again. You will be farting about a little bit with cable adjustment for the next week to get it back how you like it.

Good effort man..it is all good.

Now, beer time...

[iDemonix]

Sorted. Took all the adjusters off again, put them back in and tightened them up, put it in to the lowest gear it'd engage, pushed it forwards and let the clutch out and after a bit of fucking about it went in to neutral. Fired it up and apprehensively let the clutch out, it works!

Thanks for the advice, I'm at the girlfriends having a beer now I got REALLY worked up over that rounded bolt and clutch nut, I have a short temper so I've just been worrying and getting annoyed over everything - sorry!

Took it for a slow ride and it works well, just rode it to the girlfriends and it got here fine. It's weird, I've been so used to having a shit clutch - I stalled it three times and I'm having to relearn the biting point as it's so different now. Also when I engine brake, before it was smooth, now when I drop a cog it rips me out my seat - same for when I accelerate. There's a stretch of road that my old clutch would get me to about 90mph with much slipping, got to (edit: 70mph) pretty easily earlier and easily could of done more - it's a different bike!

Sorry for all the posts