Clutch Rod Problem

I'm having a bit of a problem getting the slave cylinder back on the bike after changing the front sprocket. My buddy has an '02 and picked up a 15 tooth front sprocket. I'm going to get a new chain and sprockets once it starts snowing and thought I'd give his 16 tooth front a go on my '99 before ordering new parts. I had planned to go two up on the back, but given the chance to try one down in the front for a while figured it was worth it.

He brought his bike over to my place. I had my sprocket out just before he arrived. We took his 16T off and put the 15T on, put the slave clutch cylinder on and tightened his chain a bit. Went to my bike, put the 16T sprocket on and could not get the slave clutch cylinder on.

We took it off, cleaned everything, put it back on, but cannot get the assembly to go on all the way. After a lot of messing around we realized it was because the clutch rod is sticking out farther than it should be. There are a couple of lines on the rod where the seams would have been, but it appears to be sticking out about a 1/4" too far.

In the process of trying to get it back together and adjusting the chain, we had the bike up on the centre stand and back down a few times and happened to pull the clutch lever while it was disassembled. We ended up bleeding the clutch, but we're both at a loss as to what is keeping the clutch rod from going in all the way.

Would moving the bike have shifted something on the other end. Reading all of the clutch posts that seem relevant the only ideas I've gained are bleeding the clutch (which we've already done), taking the slave cylinder apart and cleaning, refitting it (also done), and possibly using the brakes while spinning the rear tire (I'm not sure if this will do anything, but at this point I'll try anything).

Does anyone have any ideas? I'm at a loss at the moment.

Thanks,
Steve.

 

It could be that rod got out of it's seat in the bearing on the other side, in the clutch basket assembly. It is about 1/4" hole where it seats.
Actually, it is a two part contraption, with a hat-like blind spacer mating to a bearing, which is in the clutch press plate.
You could try to wiggle the rod a bit and see if it would seat. If nothing else works, you may have to open clutch cover on the right side and inspect the mating hat/bearing, but that is a pain and lots of work for a simple misalignment

Of course, this is just an idea what could be wrong, I could be totally off.

 

I finally got a chance to look at it again tonight. Turns out it was just the piston in the slave cylinder fully extended that kept us from getting it back together. The clutch rod seemed to be sticking out pretty far, but apparently that's where it belongs. Accidentally pulling on the clutch (force of habit) when moving the bike forced air in and locked the piston up solid. Had to use a C-Clamp to free it up and it popped pretty good, but didn't appear to damage the seal.

That will be the last time I do some work on one bike, move to a second bike and work on it, then back to the first bike. Moving it around in the process was probably my downfall though.

Glad it wasn't something in the clutch basket assembly. All I wanted to do was change the sprocket, not disassemble the entire clutch assembly.

 

Glad to hear it was nothing bent or any other serious issue. I am myself guilty of pulling clutch with open slave cylinder, but I never experienced a stuck piston because of it ... I guess shit happens

 

My experience with slave cylinders is that you have to replace them with new, brake calipers on the other hand respond well (to the labourous chore of cleaning behind the seals.)

Sometimes you can get away with using the old seals if they are not ugly looking (look under magnification) anywho000)) Cheers