I mentioned replacing my clutch-cable a little while ago, and mentioned that I needed to replace the clutch-return-spring TOO, which I found out as I was attaching the lower cable end, as an end was broken-off.
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As I have a SERVICE MANUAL I looked for guidance there BEFORE getting into the job, and this is what I found:
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Looking at the MANUAL I saw the "NOTICE" [Do not remove the clutch release lever and shaft assembly unless it is absolutely necessary.]
I was at a loss as to HOW to REMOVE the broken spring and put the NEW spring on UNLESS I removed the "Release Shaft" first, so I DRAINED THE OIL and removed the MANY bolts holding the clutch-cover to the engine, but BEFORE I could do that I needed to remove my SW-Motech 'skid-plate' and loosen my SW-Motech 'crash-bars' to access SOME of those MANY bolts!
I was getting ready to remove the clutch-cover.... As I looked at the "Release Shaft", I discovered that I could rotate it thru a bit OVER 90 degrees, and thought - "Maybe I can just pull the shaft out vertically W/OUT disturbing anything behind the clutch-cover...", so I moved the lever close to where I remembered it being during 'normal operations', and EASILY pulled it out vertically.
I was VERY PLEASED when I discovered that NOTHING ELSE came out w/ the shaft, and it was just a minutes' work to remove the broken spring and replace it w/ the NEW one (making sure that the new one went in the proper way!), then GENTLY push the shaft back down the hole in the clutch-cover.
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Then I attached the lower end of the clutch-cable, noticing that the "Release Shaft" NOW would move thru a bigger arc than it had before, then attached the other end to the clutch lever. The lower end would STILL move thru a bigger arc, but I HOPED it was OK...!
As I hadn't removed (or disturbed) the cover, I put the MANY small bolts back in, then torqued them to the proper tension, and filled the engine w/ oil as before. I started the engine and tried the clutch lever, and changing gears, but figured I needed to get the cable adjusted AT LEAST CLOSE TO THE PROPER amount, which I did on the lower adjusters using two 8mm open-end wrenches, then re-started the engine and tried shifting (on the paddock-stand of course!), and ALL felt NORMAL!!! Then shut the engine down.
NOW I needed to re-attach the SW-Motech 'crash-bars', as they include the rear engine-mount, so I got onto THAT, and once EVERYTHING looked right I replaced all the fairings that I'd removed to do this job,
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then went for a ride, looking for anything that didn't 'feel right' or was leaking.
YIPPEE! ALL was good, so I continued on a half-hour ride (w/ my heated grips set at LEVEL THREE - mid-range), and planned to write this up so it MIGHT help someone else w/ a similar issue...!
As I have a SERVICE MANUAL I looked for guidance there BEFORE getting into the job, and this is what I found:
Looking at the MANUAL I saw the "NOTICE" [Do not remove the clutch release lever and shaft assembly unless it is absolutely necessary.]
I was at a loss as to HOW to REMOVE the broken spring and put the NEW spring on UNLESS I removed the "Release Shaft" first, so I DRAINED THE OIL and removed the MANY bolts holding the clutch-cover to the engine, but BEFORE I could do that I needed to remove my SW-Motech 'skid-plate' and loosen my SW-Motech 'crash-bars' to access SOME of those MANY bolts!
I was getting ready to remove the clutch-cover.... As I looked at the "Release Shaft", I discovered that I could rotate it thru a bit OVER 90 degrees, and thought - "Maybe I can just pull the shaft out vertically W/OUT disturbing anything behind the clutch-cover...", so I moved the lever close to where I remembered it being during 'normal operations', and EASILY pulled it out vertically.
I was VERY PLEASED when I discovered that NOTHING ELSE came out w/ the shaft, and it was just a minutes' work to remove the broken spring and replace it w/ the NEW one (making sure that the new one went in the proper way!), then GENTLY push the shaft back down the hole in the clutch-cover.
Then I attached the lower end of the clutch-cable, noticing that the "Release Shaft" NOW would move thru a bigger arc than it had before, then attached the other end to the clutch lever. The lower end would STILL move thru a bigger arc, but I HOPED it was OK...!
As I hadn't removed (or disturbed) the cover, I put the MANY small bolts back in, then torqued them to the proper tension, and filled the engine w/ oil as before. I started the engine and tried the clutch lever, and changing gears, but figured I needed to get the cable adjusted AT LEAST CLOSE TO THE PROPER amount, which I did on the lower adjusters using two 8mm open-end wrenches, then re-started the engine and tried shifting (on the paddock-stand of course!), and ALL felt NORMAL!!! Then shut the engine down.
NOW I needed to re-attach the SW-Motech 'crash-bars', as they include the rear engine-mount, so I got onto THAT, and once EVERYTHING looked right I replaced all the fairings that I'd removed to do this job,
then went for a ride, looking for anything that didn't 'feel right' or was leaking.
YIPPEE! ALL was good, so I continued on a half-hour ride (w/ my heated grips set at LEVEL THREE - mid-range), and planned to write this up so it MIGHT help someone else w/ a similar issue...!
