Author Topic: New clutch not working at all! (Read 13451 times)

unfazed · « **Reply #25 on:** 30 March 2016, 09:21:34 pm »

Most important is buy a manual and/or download the one in the downloads section. Watching a youtube video is not the best way to go and should only be used with a manual, I am not saying not to watch them but a manual is something which shows all the pieces associated with what you are dismantling. The fellow in the youtube video you watched was neither an experienced DIYer or Mechanic. However do not let it put you off and learn from the experience
See pic below

sc0ttie · « **Reply #26 on:** 30 March 2016, 09:44:09 pm »

No I did not remove that part, i did not touch any part inside there where the bolts go, I didnt need to, I just undid the bolts removed them with the springs, then gently prised off the pressure plate and then slipped the friction plates off, slipped new ones on, screwed pressure plate back on with springs.

Deefer666 · « **Reply #27 on:** 31 March 2016, 09:54:36 am »

The ball bearing can come out from either side, chances are is was stuck to the shorter of the 2 push rods. I would be more concerned with where it went, If it dropped down into the sump in has the potential to cause a whole load of problems

Fazerider · « **Reply #28 on:** 31 March 2016, 10:20:35 am »

Quote from: sc0ttie on 30 March 2016, 09:44:09 pm

No I did not remove that part, i did not touch any part inside there where the bolts go, I didnt need to, I just undid the bolts removed them with the springs, then gently prised off the pressure plate and then slipped the friction plates off, slipped new ones on, screwed pressure plate back on with springs.

In that case you didn't lose the ball bearing. If it's missing now then it's the garage that dropped it.
Not that the absence of ball has anything to do with the problem of no drive to the back wheel.

celticdog · « **Reply #29 on:** 31 March 2016, 11:55:40 am »

It's a 5/16 inch diameter ball if you need to find a replacement, 93505-16006.
Do you have a magnetic sump plug? Could be stuck to it with a bit of luck, lets hope you find it either way.

Kelevvra · « **Reply #30 on:** 01 April 2016, 11:35:01 pm »

Like Fazerider said, if You did not remove the part in the middle - garage must have lost the ball. I had same problem after fitting new plates and EBC springs. Could not figure it out for ages. In the end went back to old springs (actually to 6 long ones off Thundercat - they are identical - loong story

... and it worked. It seems to me that heavy duty EBC springs are too stiff.

Deefer666 · « **Reply #31 on:** 02 April 2016, 07:40:11 am »

Having re-read your original post, if its EBC springs that you fitted the listing is wrong and the springs are too long. I had this with a customers bike. In the end I had to contact EBC and get the part reference for the correct part

sc0ttie · « **Reply #32 on:** 02 April 2016, 05:41:38 pm »

Quote from: Deefer666 on 02 April 2016, 07:40:11 am

Having re-read your original post, if its EBC springs that you fitted the listing is wrong and the springs are too long. I had this with a customers bike. In the end I had to contact EBC and get the part reference for the correct part

I tried refitting the old friction plates though, with the old springs and the clutch still did not disengage. Anyway, the shop have now fitted me with EBC clutch kit, new oil and new springs, they collected my bike for me in their van last weekend. It came to £210 with labour costs, which was a bit of a shock, but they supplied the ebc kit, new oil and also got the ball bearing out of the sump with a magnet. As a lesson to myself, I need to be more careful when i attempt DIY mechanics at home and also, I need to not buy cheap unbranded parts. FYI the clutch plates I got were a kit costing £27 on ebay, which I obviously did to save money but it ended up costing me more than it would if I had got the garage to do it in the first place.
Thanks to everyone on here who tried to help.

Bretty · « **Reply #33 on:** 02 April 2016, 07:35:55 pm »

Glad you got it sorted. I'm unclear as to what your problem was the clutch engaging or not engaging?

sc0ttie · « **Reply #34 on:** 02 April 2016, 11:31:33 pm »

I could put it in gear and sit there revving the engine with the clutch lever out, no matter how i adjusted the cable, they bike did not move.

sc0ttie · « **Reply #35 on:** 05 April 2016, 07:07:22 pm »

My new clutch was slipping, so i figured i need to adjust it at the sprocket cover, so erm, i was doing that.....(btw I have adjusted the clutch cable here a few times before, when my old clutch started to slip so i know how to do that) anyway, i guess I may have unscrewed the screw/nut too much as somehow the cable has come off where it should be attached, behind the sprocket cover.

Thinking I could just take the sprocket cover off and reattach the cable, i started to take the allen bolts off the cover, got to the last allen bolt and guess what? its rounded off very badly, my attempts to get it off with a torx fitting made it even worse. Because it is in a sunken recess it is actually quite difficult to get to. After the torx bolt failed I figured I would drill the bolt head out so that i could get the sprocket cover of and reattach that cable. I could not drill it out, i tried loads of times, either my drill bits are very blunt (could be as they are old) or that is a very strong bit of stainless steel. So the allen bolt is still stuck, rounded off from drilling now the centre now as well. What can i do to get this allen bolt off? I dont have a dremel, I dont have the money for one either.

I am going to have to take a day off work to sort this out now because the bike is un-rideable once again for the 2nd time in 2 weeks!

fazersharp · « **Reply #36 on:** 05 April 2016, 08:20:03 pm »

You are not having a good time are you.
I thought the clutch was done by a garage so why haven't they adjusted the cable properly or sounds like they didn't even test it.

Here is some info on what you will find when you get the cover off http://foc-u.co.uk/index.php/topic,16751.msg193276.html#msg193276

I think you need a new drill bit

sc0ttie · « **Reply #37 on:** 05 April 2016, 08:37:59 pm »

I'm not have a good time no lol. The clutch was ok the first day, it started slipping a bit the next day, then the day after that (monday) it was slipping more so decided tonight to try and adjust the cable. The garage did say they rode around on the local A road for 5 miles or so before I collected the bike to make sure clutch was ok.

I will try a new drill bit tomorrow, wilkinsons should be open, its my nearest tool store. With some luck i can drill that bolt out and then fit the cable back in place, tension it etc. I hope...

fazersharp · « **Reply #38 on:** 05 April 2016, 08:45:51 pm »

Get the most expensive ones they do to give yourself any chance and also get a few because they may well blunt quick AND snap.
Im no engineer and hate drilling metal cause I haven't got the patience that is needed.

Someone better than me we be along soon to advise on drilling

His Dudeness · « **Reply #39 on:** 05 April 2016, 08:57:39 pm »

A picture of the bolt would be good

Bretty · « **Reply #40 on:** 05 April 2016, 10:44:49 pm »

To be honest, rightly or wrongly (yeah yeah, I know wrongly).. any steel Allen key bolt screwed in to aluminium, I always loosen with an impact driver. Like a screwdriver that turns when you hit it with a hammer. I just put an Allen key socket on the end and tap out. Any screws in a dissimilar material or subject to thermal variation will fuse/corrode in. The impact driver never rounds heads and will get any screw moving.

Screws can be a nightmare to get out once rounded, always start with dremel, either disc cut a slot and wind out with a screwdriver, or engrave a dimple, the drill out with progressively larger size drill bits. small bits.

sc0ttie · « **Reply #41 on:** 06 April 2016, 02:26:23 pm »

Well, 6 drill bits later and 2 trips to wilkinsons I still don't have that $&*$ bolt off. I have now called a bike shop who will collect it tomorrow for me and sort this out. I am so done with this, i took the day off work to do this lol

unfazed · « **Reply #42 on:** 06 April 2016, 02:43:01 pm »

Quote from: sc0ttie on 06 April 2016, 02:26:23 pm

Well, 6 drill bits later and 2 trips to wilkinsons I still don't have that $&*$ bolt off. I have now called a bike shop who will collect it tomorrow for me and sort this out. I am so done with this, i took the day off work to do this lol

High quality HSS left hand drill bits and reversible variable speed drill are your friends here.

Or move closer to a foccer who is handy with tools

(for the twisted among you I did not say "With his his tool")

sc0ttie · « **Reply #43 on:** 06 April 2016, 02:55:58 pm »

Lol I phoned a few mobile mechanics locally and they were not interested in it either, even local scooter garage said they couldn't collect it. I was buying HSS drill bits, it says on it titanium coated carbon steel for all metal alloy etc. Just not my allen bolt lol. I only have a high speed drill, will have to ask the girlfriend to get me a multi speed drill for my birthday. Anyway, not using the same bike garage i used before, its good to try a few and see how they compare I suppose. If I get told my clutch cable has stretched and that is probably why it was slipping, i will eat my hat!

fazersharp · « **Reply #44 on:** 06 April 2016, 03:29:45 pm »

Quote from: sc0ttie on 06 April 2016, 02:26:23 pm

Well, 6 drill bits later and 2 trips to wilkinsons I still don't have that $&*$ bolt off.

I did tell you ----------- sorry

Quote

get a few because they may well blunt quick AND snap.

Too much speed will also blunt/burn the bit out

Fazerider · « **Reply #45 on:** 06 April 2016, 04:12:08 pm »

A bit late now, but allen bolts are made from harder material than ordinary drill bits can cope with.
Titanium coatings on HSS are fine for making the bits look pretty and they're ok for anything up to mild steel, but you need tungsten alloy or cobalt alloy bits for drilling high carbon and stainless steels. And a slow drill.

unfazed · « **Reply #46 on:** 06 April 2016, 06:16:52 pm »

Must check what mine drill bits are as I have drilled a few of these bolts and stainless bolts over the years, but always with a variable speed drill at low speed. Have also drilled the case hardened sprocket shaft and tapped it to fix my sprocket nut issue.

I believe the secret is really sharp tools, lubrication and patience coupled with plenty of time

Hawko · « **Reply #47 on:** 23 May 2016, 09:59:50 pm »

Soi did the same plate change with the EBC spring etc, and now the gear shifter wont move at all. Just hope I havent bent anything...