Turns out I'm more talented at making problems than fixing problems when it comes to bikes..

I took the front sprocket cover off to check the wear. When I put it back on, I had the bike in first gear with the clutch lever pulled in and I can't spin the rear wheel while on the stand..

Took the sprocket cover on to check the clutch mechanism. When I pull the clutch cable, the little cylinder pushes out smoothly and goes back in when I let go of the clutch cable. When I put the cover on, the little cylinder is definitely going over the rod, but it's still not doing anything.

When the sprocket cover is off and I try to push the rod I can't get it to move. Should it be able to move when pushing it by hand?

Ideas?

Cheers

Easy one dude..

The inside of the cover has a little grommet that sits insidethe mechanism. It will have moved or been dropped etc

Make sure it is in the cover and when you turn the clutch actuator that you can feel it pushing in and out.

CMSMJ1 wrote:Easy one dude..

The inside of the cover has a little grommet that sits insidethe mechanism. It will have moved or been dropped etc

Make sure it is in the cover and when you turn the clutch actuator that you can feel it pushing in and out.

Hmm don't count your chickens just yet, Mark!

The little grommet you're talking about.. Is this a little hollow cylinder that goes in the hole towards the bottom of the shaft on the LHS of the sprocket cover, and when the clutch cable is pulled it pops its head out, pushing the rod? If so, that is in place and when I pull the clutch cable it does stick its head out as it should.

Yes, that bit.

You can make it go in but it does ont always sit in there properly. Have a play with it..it will be this bit..as most of us have done this before

CMSMJ1 wrote:Yes, that bit.

You can make it go in but it does ont always sit in there properly. Have a play with it..it will be this bit..as most of us have done this before

Yeah I pulled the shaft out (what you refer to as the actuator) which the cable pulls, and it makes the little cylinder pop out and made sure it was seated properly (so the cut out is where the cylinder sits, so when the shaft is turned by pulling the cable, the cylinder is pushed outwards).

I removed it and put it back in 3 times but still couldn't get it working. Although I guess you're right.. There's not much else it could really be since nothing was changed. It probably just isn't sitting in its place 100% right.

Cheers Mark. Will go outside and play around with it :)

Mark is spot on with this, just keep playing with it the penny will soon drop

OK I'll go give it another try :)

Hey Munky let me know prices and what coloured springs you've got when you get time :) I have a track day Feb 6th so need to get it sorted soon because postage will take a week or 2 then I need to get it installed and make sure it's all good :)

Here's a picture of my baby. Isn't she beautiful??

I just had another try and still no success. The cylinder shaped pin that pushes the rod is definitely sitting properly and definitely pops out the whole way when the clutch cable is pulled. The clutch cable is definitely attached properly and the cylinder is definitely sitting on the rod when the cover is installed.

When I put the sprocket cover on and pull the clutch lever, I can only just move the rear wheel with all my force behind it so I guess the rod isn't being pushed the whole way in.

When the cover is in, with all my force I can't push the rod in at all. Is this normal or should it be pretty easy to push in? Perhaps rod isn't going into its desired hole at the end? Maybe I should try tapping the rod lightly? (with the cylinder shaped thing on it so it doesnt damage the curved end of the rod)

Ideas?

The rod pushes on the clutch pressure plate - don't be hitting it as it will not do anything..

I would take the cover off, take the arm out the cover, have a good look and visualise the thing working.

Unless you have got issues at the lever or have wound off the adjustment on the cable (to get the cable nipple out the arm?)

The little bucket/cap/jobby is the problem - or rather it is the arm that is pulled by the cable - stick at it man..

It is a simple part - nothing else to go wrong

hmm I had a chat with my mechanic friend and he says I shouldn't be able to push this rod with my hand. He also said the rear wheel shouldn't move easily when the bike is in gear with the clutch in so I guess I was just paranoid thinking the wheel should move almost as freely as when it's in neutral...