UJM Gearbox/clutch Issues - 2002 GSXR750
Posted: Tue Apr 17, 2012 11:18 am
This is the vehicle in question. My nephew made it from his trashed 2002 Suzuki GSXR750.
Cable actuated clutch.
He did admit to me last night that he had to make his own clutch cable, which he did from a length of plumbing snake covered with heat shrink tube. So no, no teflon inner sleeve on this one...
And yes, the powertrain has been abused since the conversion. He built it because the bike's frame was broken on one of the large spars up on top by the gas tank on one side. He did this as a lark.
Now, it acts as if the clutch won't release. When it is in gear, the rear wheel is turning regardless of the position of the clutch lever.
Mind you, this is VERY much a bodge job, and right now he doesn't even have a working clutch pedal up front. He is just pulling on the end of the cable with a pair of locking pliers.
In his first act of desperation, he ordered a clutch kit and installed new plates and springs. It made no difference.
It is VERY likely that he destroyed the transmission in his shenanigans. He was constantly having heating issues on the engine due to the stock location of the radiator. But the engine still starts easily and responds to throttle well.
I took a couple of pictures for visual reference, but those of you who might be able to help me won't need them.
This first one is the clutch throwout pushrod from the left side of the engine. It goes through the gearbox to the clutch on the right side. I saw the throwout bearing & races last night, everything looked good.
This one is the cover that goes over the push rod. It contains the actuator that is a ramp system to transfer the rotational energy into lateral.
The tip of the push rod goes into that hole. We have not taken this assembly apart any further, although it can be.
So what do you guys think? Is it time for the recyclers? (I do.)
Cable actuated clutch.
He did admit to me last night that he had to make his own clutch cable, which he did from a length of plumbing snake covered with heat shrink tube. So no, no teflon inner sleeve on this one...
And yes, the powertrain has been abused since the conversion. He built it because the bike's frame was broken on one of the large spars up on top by the gas tank on one side. He did this as a lark.
Now, it acts as if the clutch won't release. When it is in gear, the rear wheel is turning regardless of the position of the clutch lever.
Mind you, this is VERY much a bodge job, and right now he doesn't even have a working clutch pedal up front. He is just pulling on the end of the cable with a pair of locking pliers.
In his first act of desperation, he ordered a clutch kit and installed new plates and springs. It made no difference.
It is VERY likely that he destroyed the transmission in his shenanigans. He was constantly having heating issues on the engine due to the stock location of the radiator. But the engine still starts easily and responds to throttle well.
I took a couple of pictures for visual reference, but those of you who might be able to help me won't need them.
This first one is the clutch throwout pushrod from the left side of the engine. It goes through the gearbox to the clutch on the right side. I saw the throwout bearing & races last night, everything looked good.
This one is the cover that goes over the push rod. It contains the actuator that is a ramp system to transfer the rotational energy into lateral.
The tip of the push rod goes into that hole. We have not taken this assembly apart any further, although it can be.
So what do you guys think? Is it time for the recyclers? (I do.)
