Clutch Cable Holder Bolt dropped down

[Rikin]

Hi,

Ive removed my old clutch cable (zxr400 L1) and the long vertical actuating bolt has dropped down a few inches. When I try to push it back up, it stays out ever so slightly, and also when I rotate it it doesnt turn the clutch. It spins freely.

How can I put this back in???

[RedexRobB]

Im afraid you shouldnt have undone that, that bolt is responsible for the cam chain tensioner if im not mistaken.

this is a favourite topic for Cargo, so ill let him explain how to fix it.......

[Rikin]

No, I should clarify.

I have not undone any bolts that screw into the block. The bolt I am referring to is the one that has the clutch cable swivel holder on the end of it.

This is the actual clutch engage rod that links the cable to the clutch assembly.

I have tried to swivel it around in various positions for ages, and tried to push it up in while doing the same, but it doesnt seem to do anything!

[Rikin]

It doesnt seem to stay out, actually.

It goes all the way in, but doesnt engage anything no matter what I do.

Is there a special sequence ?

[Mori Man]

Sounds like you've been doing it right , from the normal sitting position if you lower the rod down it will not locate as your hitting the tip of the clutch centre pin so you rotate rod anti clockwise until it drops and then bring it back where it should stop at about same position you started. The tip of push pin has now located into the rod, with this rod out you can clearly see the track that this sits into.

If nothing is happening did you inadvertinaley whallop the rod down with a 5lb mash hammer and snap the tip off the pin ? If so you'll need to remove clutch cover and find the tip plus replace the pin.

They are not in a habit of sheering themselves but if you can't get the rod to engage its gone !!

Good luck,

MM!

[Rikin]

I havent hit it - it came down very easily....???

Is that a sign of a problem?


No matter what I try, there is nothing there to "engage"........

Anyone in London - HELP!

[Tirpitz]

Best thing to do is remove the clutch cover and see what's happening inside. That's your next step.

[Rikin]

OK...


Do i need to drain the oil?

Do I need to buy gasket for it?

[Mad Phil]

Yes & Yes best to incase it splits

[Tirpitz]

If your oil is pretty fresh and you keep it clean when you drain it you can put it back in and save yourself a bit of money. Clutch cover gasket from Cradleys (number at top of page) will be with you next day so if you are not absolutely desperate for the bike on the road you could see if you can reuse the gasket and order when you do the job if you find you need it. TBH I would probably replace it but the worst that can happen if you don't is that you'll get an oil leak, which you could then sort by doing a replacement (after dropping the oil again )

[cargo]

If you remove the clutch cover with the bike on the side stand little or no oil will escape when the cover comes off.

Better still make sure the foot of the side stand is position in a dip on the ground or park the bike on slightly higher ground that where the side stand will go so that it leans over a little more.

[Rikin]

Thanks guys.

Pls tell me, as I have no working knowledge of clutches, what should I be looking for, how should I position the long bolt, and does anything fit to it to stop it from slipping down again?

Ive spoken to a couple of (non ZXR) motorcycle mechanics they say it shouldnt have dropped out freely, and that there must be some kind of problem???


Im about to remove the cover this evening.....

[Rikin]

Anyone please?

[Mad Phil]

Pin in the top LH Corner
http://zxrworld.co.uk/coppermine/displa ... =99&pos=69

Pin in the top LH Corner

[Mori Man]

Part Number 46102-1030 Rod,clutch

You can see it has a machined groove near the top, this located into the cut on

Part Number 13102-1097 Release-comp-clutch