Clutch Rod Into Engine?

[jaysern]

Hi All, I've attached 2 photos that better describe this.

My clutch cable snapped and I was trying to replace it, when I accidentally removed this (rod?) that inserts into the engine vertically.

I put it back in, but as I try to hook up my clutch cable, I notice that it comes out (up) slightly, leaving a small gap (see arrow).

The picture without the arrow is when it's fully down, no gap.

I'm not sure if this is normal. Any advice? It's a Kawi 2004 636.

Thank you

 

[motomania2007]

That rod should not come up like that. I suspect there is a clip or something missing INSIDE the clutch cover.

Now that you have the rod back in, does the clutch function properly?

 

[RickM]

On most bikes that clutch actuator arm/shaft just pulls up once you disconnect the cable and swing it like 30 degrees back. It's held in place by the groove in the clutch rod (to which the shaft attaches)itself and the cable preventing it from swinging back enough the disengage from the clutch rod groove.

To put it back in correctly, swing the arm away from where the cable would pull it normally and push it in and then swing it back towards the cable and connect the cable.

 

[jaysern]

Thanks guys!

motomania2007 - I'm pretty sure I didn't lose anything, all the parts are there, and my bike was working before. I'm afraid to start my bike until figuring this out, so I don't know if this works yet.

RickM - If I understand you correctly:

1. I need to swing it away, and push it down (like in the pic above without the arrow)
2. Then I need to swing it back towards where I need to connect the cable (which is really hard) *WHILE* keeping the rod down (because it does want to pop up).

Is that right? That 2nd part is really hard to do. Any tips on how to do that? Might be a two person job. Even just connecting the cable is hard enough.

 

[stangmx13]

get the factory service manual and check those instructions. u can prob download the manual in pdf form if u google for it. the procedure should be very easy. there should be enough slack in the cable to attach it without having to actuate the lever/disengage the clutch by hand.

 

[RickM]

The slight gap is OK. you don't have to keep it pushed all the way in while putting the cable on.

It's usually easier the install the cable at the engine end first and then connect the cable to the lever.
If you have it connected to the lever already, disconnect the cable from the lever and try again. I assume you already have the adjusters turned all the way on for max slack.

 

[jaysern]

Ok, I will give it a try. I wasn't sure if the slight gap was ok. When it pops up slightly with the tiny gap, I was worried that it's not "engaging" on the inside.

I will try to google for the manual later.

Thanks!

 

[EastBayDave]

I don't think it's in correctly when the "gap" is showing. As already mentioned, you need to find a Service Manual showing both ends & install/removal of the cable/lever. This link shows the part (lower right of pic), but doesn't show install procedure. Note there's a spring & washer on bottom of clutch rod.

You need to see that procedure to be sure of correct installation process. It's out there somewhere...

http://www.ronayers.com/oemparts/a/kaw/500b27bdf8700223e47923ec/clutch

 

[jaysern]

EastBayDave: I do have the washer and the spring.

Is this one of those things that is safe to trial by error? I'll try install it without the gap, but if I can't, is it safe to start my bike with the gap (and then see if the clutch works) ?

 

[EastBayDave]

You need to see that procedure to be sure of correct installation process. It's out there somewhere...

Again as above, find a manual to see the install process to be sure it's going together correctly. Someone on here, a bud, online, etc. Someone must have that page in the service manual handy...

I wouldn't take the chance myself for fear of screwing up the clutch assembly by doing it wrong. Just go on a search online. I'm sure there must be a 636 website/blog/users group online that can help you out.

I'm part of both the ZX12R & ZRX groups online & everyone is always eager to help someone w/a question like this. Better than causing an expensive repair if something goes wrong. I know the zrx folks would be happy to help; several of them likely have older Kaw's. Go to ZRXOA.ORG & ask the question. You will have to register = it's free ! :teeth

I'm sure there's a 636 group online. Find it & ask for help. Don't be in too big a hurry to toss everything back together; only perhaps to get it wrong. Someone out there has the answer = search. If worse comes to worse, I'm sure a dealer mechanic would let you look at a service manual page for the answer..., or just phone a dealer mechanic & ask the question?

Here's another example:
http://www.kawiforums.com/usa/

-ebd

 

[Gawernator]

Hey you might get a lot of help at the zx6r forums. I have the service manual but for the newest bikes. If you wanna bring the bike over we can check it out

 

[jaysern]

Update:

I don't think that gap is normal. I didn't try starting the bike up, but after I install it, there's literally no tension when I pull the clutch lever. And when I pull out the rod, I start seeing some signs of new fresh abrasion, likely from the few times I tried pushing it down, while rotating it to the clock-wise. I made a video and some close-up photos:

https://www.youtube.com/watch?v=aBIamD9n8vA

 

[Rob]

I've never seen the inside of an atom before... thanks! :teeth

http://www.kawiforums.com/how-tos-faqs/101897-how-replace-your-clutch-plates.html

He mentions spinning it 180 degrees.

 

[stangmx13]

stop guessing. get the service manual.

 

[jaysern]

Ok, 2nd attempt, with more photos and video.

Not sure if this is a factor, but I'm not sure what gear my bike is in. It's either in neutral, 1st, 2nd, or even 3rd.

While moving it in a circular motion either direction, I do not feel anything catching inside.

I heard someone say I should start inserting the rod at a more counter clockwise position, like at 5 or 6 o'clock, but it really won't go in until at around 8 o'clock (see video).

And I think the reason why I can't put the rod in at the 8 o'clock position is because this little piece, circled in pink. I think that's what's blocking it anyway, I'm not entirely sure.

https://www.youtube.com/watch?v=aBIamD9n8vA

http://i.imgur.com/NgKS18a.jpg

 

[jaysern]

Actually, I just realized that I must be in neutral, because I can move the bike back and forth a few feet.

 

[jaysern]

So, I got the service manual but it doesn't specifically mention how to put the rod back in.

http://i.imgur.com/8yhtCnf.png

http://i.imgur.com/HqtjTLi.png

 

[buellistic]

I've never seen the inside of an atom before... thanks! :teeth

http://www.kawiforums.com/how-tos-faqs/101897-how-replace-your-clutch-plates.html

He mentions spinning it 180 degrees.

No kidding the text box is so small I cont spellcheck or SE my pic...
I can't find the reply kee.
There it is right under my microscope...

 

[jaysern]

Alright, so I finally got it in! (that's what she said! XD)

I had to put the rod in first, with the cabled hooked up, then only I hooked up the cable to the hand lever and install that.

Now I got a different problem. My bike won't start. It was working just fine before my clutch cable snapped.

I thought it was gas, so I got some gas, and I put a whole gallon in.

I did also just change the synthetic engine oil, and I put 3 quarts in. I noticed that when it's tilted on the side stand, the oil level is just above the minimum, about 1/3 full, but when it's on the rear stands, it's below minimum. So I got another quart, and now I've got 4 quarts in it. It still won't start. Videos below.

This is when I had 3 quarts in, and before I added a gallon of gas:

https://www.youtube.com/watch?v=6qrltGIv7pY

This is after:

https://www.youtube.com/watch?v=0o6YQibXVYo&feature=youtu.be

Is this whole not starting problem related to the clutch cable or rod? I don't think so, right? But I'm not sure what else could be going on. I rode it home after the clutch cable snapped. While it was snapped, I changed the engine oil. That's the only 2 things that changed.

 

[Maddevill]

If your bike has a clutch safety switch check that. It's usually right up under the clutch lever. It sounds like it's getting no spark. Verify that. If the sidestand switch or the clutch switch are acting up it will kill the ignition. And charge your battery. It sounds like it's getting weak.