Need help putting clutch cover back on 2003 VFR

OK, I took off the cover on the sproket side to replace sprocket and chain, got it all back on and the cover will not go on.
There is a long pin (rod clutch lifter) that goes through to the otherside and it will not let the cover go all the way across. When I placed the cover, it sticks out a little bit and will not go flush. I think the rod clutch lifter is out about 0.5". How do I get it back inside? i have tried shifting thru the gears and nothing.
Thanks

 

Ok after researching nag going over what I did last night, I think I might have presed on the clutch lever when putting the bike on the center stand while the clutch assembly was off, in the process maybe the piston inside the clutch assembly might have moved out therefore not allowing the clutch assembly to sit flush. My question is how do I push the piston back in? I know I need to press on but do I do that while the clutch resorvoir cap is off or do I loosen the bleed screw I instead?
Thanks

 

just tighten the cover bolts and the piston will go back in.

If you open the bleeder you will have to loosen the bolts again then pump the clutch lever then retighten it to get the clutch to work.

just go easy on the bolts and go a little bit on each bolt evenly untill the cover is seated

 

thanks!!!!
FINALLY someone responded!!!
I am really frustrated with this DYI, I was so pissed last night as I could not figure out how to get that thing back on. I had finished everthing both sprockets and chain and i counld not get it flush.
We need to bring up a point NOT TO TOUCH THE CLUTCH LEVER as you are replacing the front sprocket or else.
I will try your method tonight and I'll let you know how it goes.
thanks again for replying to my post.

 

if for any reason it is too hard and seems it will not go in ( depending on how much the clutch was pumped )
you might need to open the bleeder then snug up the bolts till the cover is seated.
then tighten the bleeder - loosen the bolts so the cover is about 1/4" - 3/8" from the case - pump the clutch - then retighten the bolts a bit at a time.
again not 1 bolt all the way - a bit on each untill seated

 

thing is that last night I open the bleeder and pushed inward on the piston and nothing, it wouldnt move. I didnt want to apply more pressure as i didn't know if I was doing the right thing. I still think that the pin (rod clutch lifter) is not all the way in.
I am buying some dot-4 brake fluid and do as you told and then flush the clutch system.
thanks

 

make sure you ck the rod ( the guide thru the motor should keep it aligned w/ clutch ), most of the time you need a small c clamp to push the piston in w/ bleeder open when the cover is off.

 

i shoved that thing in there and the clutch cover is on!!!!!!!!!!!
now I need to figure out how to bleed the clutch as I just added brake fluid to the resorvoid and nothing.
thanks

 

ok, the only thing that worked for me was during the bleeding process was to use a syringe to push the brake fluid backwards (from bleeder screw to reservoir) and voila!!!
That was the only thing that got me pressure on the clutch lever. Now I want to get more pressure on the clutch lever as the clutch is barely engaging when the lever is pressed fully and while the bike is on the center stand and in 1st gear, the rear wheel barely moves while pressing the clutch lever, which means that the clutch is still dragging. How do I get more pressure on the clutch lever? I tried loosening the bolts on the clutch slave and then pressing on the clutch lever, but as soon as I tighten the bolts, the clutch does not get any better.
thanks

 

if your bike is on the center stand in first with the clutch engaged the wheel should not move much ( it will a little )
if you have it in gear w/ clutch engaged ( on the ground ) and the bike is pushing you you have a problem.
then I would go back bleed it again and repeat.

 

ahhh, ok.
It thought that when the bike is on the center stand and in 1st gear, if I pressed on the clutch lever, the rear wheel should move freely (like in neutral), but if what you are telling me is correct then I should be goo to go!!!!!
I thought that when the clutch lever is pressed the clutch would be 100% disengaged.
Thanks

 

Dilema?

Hi, I am new to VFRs and am Having problems putting the clutch cover back on after a chain and sprocket change.
The cover was about half an inch away from the engine and seemed like it would not go any closer.
I did not want to break the speed sensor, and was pushing and pulling on the cover when the neighbor kid grabbed the bike to steady it...Only he grabbed the clutch, hard.
Now the cover is about an inch away from the engine and the clutch rod is stuck in the cover.
I can not get the cover off now because the rod is stuck and I do not want to pull it out of the engine because I do not know what might move inside there.
The cover and rod do not seem to want to go any closer to the engine even with the bleeder open.
Does anyone have any Ideas?
Thanks, Peter

 

Be sure speed sensor is fitting properly on the sprocket nut.

Same as above: Use a C-clamp to press the slave piston back with cover removed.

No harm if rod is removed from the engine.

Use caution not to over- tighten the long cover bolts or serious damage can be done. (Photos)

 

I would recommend removing the clutch slave cylinder and speed sensor from the cover during initial disassembly. As soon as you remove the bolts and get the slave cyclinder off, use a long zip tie to hold the piston in position. It is much easier to reassemble without damging things, if you remove these two items. When reinstalling the slave cylinder you have to be ready and work quickly, once the zip tie is removed.

I would also remove the actuation rod and clean it, check it to ensure it is true, and apply a light coating of good grease to it before slipping it back in place.



.

 

Thanks

Thanks guys,
Your knowledge went along way to helping me out.
I removed the clutch slave cylinder and speed sensor, and got the clutch rod unstuck from the cylinder.
I bleed the clutch slave cyl. and pushed the piston back with a c-clamp.
Reassembled everything and it all works well now. Bike is much smoother now without that kinky chain.
Cheers