My god, what have I done??? Help needed!

[EDBANGER]

OK, so I changed my sprockets and chain today. An easy job, i've done it before, but this time I have somehow really made a bollox of it.

So here's my diagram to help explain my problem. I forgot to draw the clutch cable the goes into the cover just to the left of the rubber cover.

https://img.photobucket.com/albums/v693/smncttr2/public/bikeproblem.jpg

This is the cover I had to remove to get to the front sprocket. Now past experience tells me all I need to do was remove the 5 bolts, pull off the cover and we're done. This time however, after the bolts were remove the cover was loose but would now come off. I didn't want to use brute force so investigated further. I removed the rubber cover and found another bolt. I then (this is the bit where I think I fucked it up) undid that bolts. As a result the clutch cable came loose from the case. The case still didn't shift any further so I then applied the brute force. It came off, nothing broke, nothing fell out. I figure it was just all the oily, dirt that made it slightly hard to remove and I didn't need to undo that last bolt.

I changed the sprocket, reconnected the clutch cable into it's housing on the inside of the cover and put it all back together, tightening back up that screw that was under the rubber cover.

Now, the clutch seems to be perminantly on, I can change the gears, but when I put revs on, the bike doesn't move. Then after 5 minutes of head scratching I noticed oil coming from that general area, I couldn't find the exact source but there was no leak before I started.

If any of that made sense. What the hell have I done and how do I fix it?
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If you can't spot the sucker in your first half hour at the table, you are the sucker.

[Kickstart]

Hi

That bolt (with a lock nut on it) is the clutch adjuster. From memory on the FZR600 (which uses that setup) undo it, then do it up until it just starts to make contact, back it off slightly and tighten the lock nut.

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[EDBANGER]

OK, nice one Keith. Any ideas about the oil leaking??
____________________
If you can't spot the sucker in your first half hour at the table, you are the sucker.

[Kickstart]

[Whosthedaddy]

[Kickstart]

[Whosthedaddy]

I see

I know what you mean with the clutch cable, damn fidly little thing when it comes out
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Current : MSX 125 Past : CBR 900RR Monkeybike : c50 LAC : ZXR750 H2 : FZR600 : ZX7R P3 : YW100 : TRX850: Trophy 900 T309 : GSXR 600 L0: Monkeybike : XJ6S Whosthedaddy

[Kickstart]

Mmm, and mine seems to eat them. Put a new cable in and it is light and smooth for a couple of weeks, but rapidly gets heavier.

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[cestrian]

I think the best thing to do is to remove the cover, clean the area with a cheap WD40 like spray (99p/ tin) and watch for leaks. There is a possibilty that oil may have simply collected behind that cover and maybe now its been disturbed. A clean up is not a bad thing anyway.
Just a thought....

[Rookie]

If it's the same as the Cat's setup, and it looks to be to me, that shouldn't be a problem, you just need to thread it back inside the sprocket cover and hook it back on. AFAIK though you shouldn't have to remove that black rubber thing to get at the sprocket, it's just the allen bolts, but I think there's 6, not 5... at least I remember tugging on the bugger for a good few minutes before realising there was one which was heavily recessed which I'd missed.

[EDBANGER]

[Kickstart]

Hi

Right, take the adjuster bolt and locknut out. Stick the bike in gear (engine NOT running) and try and push it forward. See if the engine turns / compare it to with the adjuster in place.

The adjuster nut should go in fairly lightly. Just turn it until you can just feel resistance as it starts to push on the clutch pushrod (not tightened right up) and the back off a touch and do the lock nut up.

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[EDBANGER]

So, take the nut and bolt out completely. Put it in gear. Am I right in saying that it shouldn't move if the clutch is out at this point?? Then put it back in and tighten it gradually until I reach the desired point??
____________________
If you can't spot the sucker in your first half hour at the table, you are the sucker.

[Kickstart]

Hi

If you take it out then the clutch should be fully engaged and it should be very difficult to push the bike forward (as the engine will turn, or the tyre skid). If it is fairly easy to push forward then you know the problem is not the adjuster.

With the adjust when you first turn it there will be next to no resistance, then you will get some resistance as you start to push on the pressure plate against the clutch springs, and then it will stop. Basically get to the point where you start to feel some resistance and then back off a touch.

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[EDBANGER]

So if it still pushes forward with the nut and bolt completely out what else could the problem be?
____________________
If you can't spot the sucker in your first half hour at the table, you are the sucker.

[Kickstart]

Hi

Clutch pushrod out of position (check if there is a locating hole on the clutch actuating mechanism, on the inside of the sprocket cover). Clutch cable catching on something, pulling the mechanism, something like that.

If it is doing it with the adjuster out then take the sprocker cover back off and try again.

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[EDBANGER]

Cheers Keith! I think next time I shall take pictures along the way just so you know what i'm on about. I'm not sure I know!
____________________
If you can't spot the sucker in your first half hour at the table, you are the sucker.