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gsxr1000 clutch prob??? |
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twistgrip 
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Joined: May/22/2009 Location: Australia Online Status: Offline Posts: 11 |
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 Topic: gsxr1000 clutch prob???Posted: August/08/2009 at 1:00am |
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Hey guys, i've just purchased a cushion kit & a complete OEM clutch pack for my K1 gixxer. my prob is when the clutch freeplay is adjusted with the required freeplay at the lever the clutch is basically unusable,bike creeps in first gear, disengages & nearlly stalls as soon as lever comes away from grip?? the only way to make it work is basically remove all the freeplay. i have fitted it and adjusted as per instructions(twice) no major wear in basket pushrod adjusted properlly Does anybody have any ideas??? was fine till i fitted this kit ?? Cheers....Desperate Aussie!!!!!!!
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tommy2671
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Joined: July/26/2004 Location: United States Online Status: Offline Posts: 583 |
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Posted: August/10/2009 at 6:21am |
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If everything is installed and adjusted correctly, There is something wrong with the clutch stack height, sounds too thick. |
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2008 KAWASAKI ZX14 (ALL BROCKED OUT)
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twistgrip
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Joined: May/22/2009 Location: Australia Online Status: Offline Posts: 11 |
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Posted: August/10/2009 at 5:30pm |
Quote: Originally posted by tommy2671 on August 10 09Yes mate i agree, the fibres all measure up to suzuki specs (around 2.7mm) The kit is definately installed properly & adjusted to Brock's specs. Does anybody know what the stack height should be ???? |
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twistgrip
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Joined: May/22/2009 Location: Australia Online Status: Offline Posts: 11 |
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Posted: August/11/2009 at 3:34am |
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ok iv'e removed the cushion & the clutch works fine??reinstalled kit & the clutch is hopeless.
should the inside diameter of the concave washer be much larger than the flat steel one??? Cheers Peter |
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*EJ*
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Joined: January/19/2004 Online Status: Offline Posts: 1016 |
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Posted: August/11/2009 at 3:45pm |
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yes the I.D. of the concave washer is larger than the I.D. of the flat washer.
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twistgrip
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Joined: May/22/2009 Location: Australia Online Status: Offline Posts: 11 |
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Posted: August/24/2009 at 4:05pm |
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still trying to sort out this prob,can somebody give me the thickness measurement of aluminium cushion please ?
Cheers Peter |
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twistgrip
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Posted: August/26/2009 at 3:22am |
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bump
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Guests
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Posted: August/27/2009 at 10:27am |
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Have you adjusted your free play lately like our instructions say? If so then I would check to make sure that your clutch cable is in good shape. |
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twistgrip
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Joined: May/22/2009 Location: Australia Online Status: Offline Posts: 11 |
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Posted: August/27/2009 at 2:35pm |
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yes have adjusted to your specs (numerous times),clutch cable seems fine & has always been regularly lubed.Removed the mod & re-installed the discarded fiber & the clutch works fine???????????????????
Peter |
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warrior14
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Joined: August/13/2007 Online Status: Offline Posts: 12 |
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Posted: August/27/2009 at 5:17pm |
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Peter, if you have installed the cushion kit correctly and adjusted everything per page 3 of the instructions, your cable is probably stretching. Check the adjustment of step 2 (page 3), there must be 1/8" of thread showing, otherwise it will limit travel in the clutch release screw assembly. Have you had the cover off and possibly the clutch release screw assembly has been assembled out of phase limiting travel. Your problem is you are not getting enough travel to disengage the clutch, this occurs with mis-adjustment and stretching cable. It is not unusual to replace the clutch cable often when running the heavier springs. Good luck and post what you find. Scott |
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twistgrip
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Joined: May/22/2009 Location: Australia Online Status: Offline Posts: 11 |
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Posted: August/28/2009 at 12:15am |
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Hey Scott, yes the cable & freeplay is definately adjusted as per Brock's specs, if the cable was sretched wouldn't i have the same issue when i go back to the stock clutch(still using Brock's springs)?? really appreciate your advice. Cheers Peter |
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warrior14
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Posted: August/28/2009 at 9:57am |
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If you assemble your stock clutch and everything works correctly, then you install the clutch cushion and lose your disengagemnt, something is not installed correctly with the kit. Before you remove your stock clutch again, measure the stack height, install the cushion kit and measure again. If the measurements are not close, you have something installed wrong. Pay close attention to everything as you assemble it and maybe you will see what is going wrong. Scott |
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twistgrip
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Posted: August/28/2009 at 5:41pm |
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what is the best way to measure the stack height?? or doesn't it really matter as long as both packs are measured the same way? . i don't know how i could be getting the installation wrong, start with the alluminium cushion(with lip) the lip end in first so it locates around the inner hub clutch surface then the flat steel washer then the concave washer(the smallest diam of the concave washer is pointing to the clutch cover or RHS sitting on bike). Start assembly with a steel (instead of fiber) discard one of the fibers,adjust cable & pushrod as specified Cheers,Peter
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tommy2671
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Joined: July/26/2004 Location: United States Online Status: Offline Posts: 583 |
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Posted: August/29/2009 at 8:04am |
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Another thing is to make sure your clutch cover isn't cracked or flexing when you pull the lever in.Measure plates with a digital vernier caliper.Aftter the clutch is installed and adjusted pull the lever in and out and watch the hat to make sure it is releasing evenly (put bike in gear) see if the rear wheel will spin with your hand (gonna need help from a buddy) as he is spinning the wheel release the lever to see when and where it is engaging, from there you can adjust your stack height(thicker or thinner).You can make sure everything is working before everything is put back together. |
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2008 KAWASAKI ZX14 (ALL BROCKED OUT)
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twistgrip
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Joined: May/22/2009 Location: Australia Online Status: Offline Posts: 11 |
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Posted: August/29/2009 at 11:34pm |
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all the fibers & steels measure to the max suzuki specs & have minimal variation(were bought new with kit),the installed measurement of both packs has a variation of .2mm(.008")the stock was the thicker one. I did notice there seems to be alot of movement in the worm drive in the pushrod adjustment assembly(up & down & sideways),it seems to lean over before it pushes forward.
Peter |
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twistgrip
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Joined: May/22/2009 Location: Australia Online Status: Offline Posts: 11 |
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Posted: August/31/2009 at 12:39am |
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i have re-installed the kit without the .020" flat steel washer & it works fine,so am thinking of machining two of the steels, one .010" thinner & one at .020" What do ya's think??
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twistgrip
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Joined: May/22/2009 Location: Australia Online Status: Offline Posts: 11 |
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Posted: August/31/2009 at 1:48am |
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I really think there is a issue with this kit.
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warrior14
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Joined: August/13/2007 Online Status: Offline Posts: 12 |
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Posted: August/31/2009 at 9:58am |
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Peter, .020" spacer will not cause the clutch to start dragging, that small amount is easily covered by the adjustments. Have you checked your inner hub for notching? .020" may place a steel in the right position to hang in a notch in the hub. Run your fingernail against the inner hub grooves, if you feel any roughness that may be your problem. This kit is running in hundreds of bikes without this problem, something is being overlooked. Scott
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