Clutch push rod alignment, Need help!!

[JSTracer]

Hi all,

I have a 2015 Tracer 900. I have just changed the clutch basket out of due to low RPM vibes which I suspect are coming from worn rubber cush dampers in the basket.

I have everything back together but I am stuck at realigning the splines of the push rod onto the gears at the end of the shaft of the actuator arm. This just seems impossible to get right, I asked the local dealer if there was an alignment tool Yamaha do but he said it just takes patience.

Wondering if anyone on here has successfully managed to get it back lined up?

If so, is there any tips/tricks or something that I am missing?

Thanks in advance. 😉

[Buggy Nate]

10 hours ago, JSTracer said:

Hi all,

I have a 2015 Tracer 900. I have just changed the clutch basket out of due to low RPM vibes which I suspect are coming from worn rubber cush dampers in the basket.

I have everything back together but I am stuck at realigning the splines of the push rod onto the gears at the end of the shaft of the actuator arm. This just seems impossible to get right, I asked the local dealer if there was an alignment tool Yamaha do but he said it just takes patience.

Wondering if anyone on here has successfully managed to get it back lined up?

If so, is there any tips/tricks or something that I am missing?

Thanks in advance. 😉

Some heavy grease can hold it in place whilst manoeuvring the cover on.

[JSTracer]

Thanks. Yeah, I'm going to give that a go next. I assume its putting grease in between where it sits in the bearing? To centralise it and give it some rigidity to stay in the 4 O'clock position?

Do you remember did you get it on flush from the front or did you go underneath from the bottom?

I've been trying to line it up lying on my back with a headlamp on trying to get the splines lined up, just before I close the cover, not the most comfy position 😒

[dazzler24]

This might help you.  Take note of the part that mentions aligning the clutch pull lever as you slide the cover back on.

This info - "I took a photo of the clutch actuator (pull lever) position just before it released from the pull rod when I was removing the cover and I'm glad I did as you must have it in that same position when reassembling for the alignment marks to realign.  I was fortunate in that I got it first go for which I was amazed!"

 

[dazzler24]

Last photo in that post is the one to be interested in.

[dazzler24]

This also might help.

Video is queued up at the right spot for what you're interested in (I hope).

 

[JSTracer]

Thanks for your replies dazzler24. Yes, I saw your topic, I will put the arm in a 10 O' Clock position before trying to align it.

That video has been very useful in doing the change but at that part he actually doesnt have the splines lined up with the gear on the actuating arm, something he admits to in the youtube comments. You shouldn't be able to move the arm with that ease with your thumb, slipper clutch or not! I've been there so many times, dot lines up with arrow but nope it aint in! 

The mechanic in my local dealer said they have a record of 6 attempts before getting it right so I knew it was gonna be a pain 😀

Thanks again for your reply

[Buggy Nate]

32 minutes ago, JSTracer said:

Thanks. Yeah, I'm going to give that a go next. I assume its putting grease in between where it sits in the bearing? To centralise it and give it some rigidity to stay in the 4 O'clock position?

Do you remember did you get it on flush from the front or did you go underneath from the bottom?

I've been trying to line it up lying on my back with a headlamp on trying to get the splines lined up, just before I close the cover, not the most comfy position 😒

I put some thick as f@{k grease and dried it off really well with brake cleaner. Centred it in the bearing and popped the cover on. First go too… 😂

Don’t be too concerned with the arm position you can take it off the splines to correct the angle.

[JSTracer]

Thanks Buggy. I assume you need ssnap ring puller or something like that to get the arm off? 

I'll bear that in mind too 👍

[Buggy Nate]

2 hours ago, JSTracer said:

Thanks Buggy. I assume you need ssnap ring puller or something like that to get the arm off? 

I'll bear that in mind too 👍

Yep just some standard circlip pliers will do.

[JSTracer]

Thanks Buggy.

Well, I took the pressure plate off again and applied lithium based grease to the push rod. I also checked what position the lever needs to be in to accept the cover, mine seemed to be closer to 11 O'clock. 

Anyway, everything tightened up, dot pointing to arrow and no clutch disengagement 😔

The tension in the clutch cable is definitely correct, all feels familiar.  My great fear now is are the clutch bolt springs tight enough? I just got all these back to their home positions and then just nipped them tight, worried about them snapping. Or  are the plates stuck together? I bathed them in oil and they have been sitting there in the basket for approx 3 weeks.

I haven't put oil back in or started the bike, wonder would this make a difference?

More help needed I'm afraid 😓