me clutch buggered orf....

andym · World Chat Champion Joined: 16 Nov 2010 Karma :

... i hope.

OK here's the script.

I was coming up to some traffic lights (on my Suzuki Intruder VL125), pressed the brakes, dropped the gears, lights changed to green so I carried on in 3rd gear only to get about 200 yards passed the lights and the speedo starts dropping rapidly. Thinking the engine will cut out I drops into 2nd release the clutch and bugger all happens, speed carries on dropping etc. I push the bike to a lay-by and try putting it in first, easing the clutch out and get no movement.

I thinks that's strange, I switch it off and restart it and still no movement, so I push it the 1/2 mile to work and try again and still nothing.

Had the engineer have a quick look at it and without taking anything apart he guesses it's either the clutch plates have effed up, the cage or the shaft running through the clutch that has ripped the splines off.

When I finished work I started it up and when I push the bike there is a definite rattle going on on the right hand side of the engine (engine starts and runs perfect), and when I put it in 1st, 2nd gear nothing happens, but when I put it in 3rd upwards there is a definite rubbing/grinding noise (not mechanically minded but sounds like it is trying to go into gear), but the bike still doesn't move.

Anyone have any ideas on this one?

The bike is still at work and I need to take the car tomorrow and throw it in the back and bring it back and strip it down and find out what damage has been done.

iooi · Super Spammer Joined: 14 Jan 2007 Karma :

So when in gear do the revs still rise, but you get no forward motion.
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andym · World Chat Champion Joined: 16 Nov 2010 Karma :

Everything runs normal, the thing I noticed was the speedometer moves when I turn the throttle

iooi · Super Spammer Joined: 14 Jan 2007 Karma :

Either clutch or the output shaft has bust.

Or could be that front sprocket has come off/sheard splines.

I would try looking at the front sprocket 1at and if its not that. Then its strip the casing off to check the clutch.
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chris-red · Have you considered a TDM? Joined: 21 Sep 2005 Karma :

Most likely the clutch. It may just need adjusting or it may need replacing.
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stinkwheel · Bovine Proctologist Joined: 12 Jul 2004 Karma :

andym · World Chat Champion Joined: 16 Nov 2010 Karma :

Now why didn't I think of the front sprocket thing first?

I'll have to check that tomorrow, I'll be pissed right off if it is something as simple as that.

I got the bike home tonight (sometimes I love driving an espace), got it into my garage and couldn't wait till the morning to start ripping it apart.

Things kinda went like this
I decided that I would just remove the clutch cable and do the rest int the morning....
.... OK I'll just take the exhaust off and that'll cut a few minutes off....
... maybe I should drain the oil out so it doesn't make a mess all over the floor....
... are those 8mm bolts... I had best check.... an 8mm socket would be much quicker than the spanner.... I'll just loosen them off....
... I'll just remove the cover and then I'll call it a night....

and now I'm stuck, I've removed all the obvious bolts, I got the casing to move, but it appears to be held by something inside. I really need some advice on this please

mad4it028 · World Chat Champion Joined: 04 Jul 2006 Karma :

theres 3 bolts not circled i guess this is oil filter and probally want removing 1st but as already said if the speedo is going up but no movement it would point to front sprocket as your speedo is driven by this so the output shaft must be spinning it wouldnt be spinning if it was a clutch fault could even be as simple as the chain coming of the front sprocket??
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andym · World Chat Champion Joined: 16 Nov 2010 Karma :

This may sound a bit stupid.... but if the sprocket is on the left hand side of the bike then why is there noises coming from the right hand side? I'll be kickin' myself if I find it is just the sprocket though.

stinkwheel · Bovine Proctologist Joined: 12 Jul 2004 Karma :

I'd remove the oil filter cover, they sometimes sneak a long bolt in there that goes all the way through.

You'll also need to move the clutch arm round so it's facing backwards (or sideways) to disengage it from the clutch mechanism.

EDIT: Could also be a totally rounded off front sprocket. I've seen some with nothing more than stumps before. Makes a hell of a clatter-up and no foreward movement.

This isn't the worst I've seen:
https://motorcycle-recycle-center.com/Wore%20out%20sprocket.jpg
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andym · World Chat Champion Joined: 16 Nov 2010 Karma :

Cheers Stink, it probably is the clutch arm holding it in place, I should have pointed out that I had removed the oil filter cover and couldn't find anything in there (well other than some oil and the filter), chain and sprockets were replaced about 700 miles ago so if its smoothed off then someone is going to be in big trouble.

How much force can I use to remove the cover? I'm worried about something breaking somewhere in the engine.

andym · World Chat Champion Joined: 16 Nov 2010 Karma :

I'm the first to admit it... I'm a muppet.... just took the sprocket cover off... and a rather large bolt fell out... also the sprocket was sitting right at the end of the shaft just waiting in line to fall off. So it'll be sorted in a few minutes.

Cheers for the help

andym · World Chat Champion Joined: 16 Nov 2010 Karma :

well that was a pain in the arse.... got everything thrown back together as good as new.... only to find the clutch lever wasn't going back out, so stripped it all down again turned the clutch pin round so the teeth were facing the right way.... spent 25 minutes trying to get the housing back on only to find the clutch lever still wasn't returning.

then realised there was a bit of slack that needed to be taken up before the clutch worked properly.

The good news is that everything is back in running order Thumbs Up