My clutch just gave up on me!

[Phxbuller]

What do I do?[sad][mad] I was hoping it was just my cable, but no such luck. Where do I get a new clutch from? And can it be rebuilt? Any help is much appreciated. Thxs

 

[Phxbuller]

I hate typing with my phone.... It just never comes out right

 

[uly luigi]

Are you sure of what happen to the clutch? there has been instances of the lip of the primary cover breaking causing it to not disengage

 

[Phxbuller]

Not 100% sure yet. I drove it home, and waiting for it to cool down before I pull it apart, and look at it.

 

[uly luigi]

just pull the inspection cover for the clutch, if that is what turned loose you wiull see it right there

 

[JOEL9]

yea, look at lip and see if it's cracked or chunks missing. might have to remove the ball/ramp assy. to see it. here is a pic. of the crack on mine.

 

[Phxbuller]

ok update....

what can i do? is it fixable? Or do i need to buy a new case?

 

[JOEL9]

Gunut75 does a fix, he did mine. i'll see if i can get in touch w/ him. or you can try it yourself.

 

[JOEL9]

i sent you a pm Phxbuller.

 

[Macbuell]

Not too bad to do yourself if you have the tools.

Happened to me too. Much better now.

 

[JOEL9]

[up]Macbuell

 

[Phxbuller]

macbuell, how did you do that? ive got a machine shop at work i can use aka endless tools. what is the measurement for the circle?

 

[Phxbuller]

oh and what thickness of metal did you use, and is that stainless steel or just regular mild steel?

 

[uly luigi]

Winner, Winner, Chicken Dinner, Sorry dude, but when you said it wasn't cable and able to ride, there was almost no question what had happened, almost every one does the fix, instead of replacing the cover, good luck, which ever route you go

 

[g3STRIKES]

any good machine shop can tig it and remachine

 

[Macbuell]

Sorry, I don't have any specs. Metal was 1/8" I think. I had to grind it down a few times until I could not feel it grinding with the cover on. Still much thicker than needed. I believe I got the ID of the hole from measuring it, then subtracted 1/4" to get the 1/8" lip...might have been 1/2" to get the 1/4" lip. Either way that does not need to be precise- just dont go TOO big on the lip and you will be fine. Just trial and error with what fits. Have the bike close to a grinder and make sure you clean it very well when done before adding oil! Don't want leftover crap in there.

 

[Macbuell]

I work a AL weld wire manufacturer and due to the casting all our guys recommended this fix over welding and re-machining. Stronger this way.

Mild steel for my plate

 

[Phxbuller]

thanks guys. i ended getting a new one from American sport bike. so i could get back on the road fast. and i must say ASB was totals awesome to deal with, big thanks to Al and Joann over there. so here are the picks from the replacement. i figure i will still fix the broken one and have a back up. i was goin to make a few of these plates just in case it happens again or to someone else, that was I've got some pre made.
draining out the oil...

the old one...

the new one after painting

here it is all put back together...

 

[bigflash1]

This is such a great forum!
Wish I had access to a CNC plasma cutter and could cut a bunch of these?