Falkonworks
Registered
So guys, I’ve been working on swapping out my stock inner hub with the Brock’s mod, for a billet one piece hub in my new motor. I ended up having some issues and realized that I was not provided all the extra hardware I would need to properly install the hub. That’s another story I will get into in the build thread once it’s finished up since it’s still an ongoing issue.
What I want to talk about in this thread is another issue I have run into while performing this modification.
I have done the clutch in the Busa twice now, and I know that when I’ve done it in the past, when installing the pressure plate you need to hold pressure against what Suzuki calls the “pusher”. This is the small steel piece with a flange that the clutch rod pushes when you pull the lever. This inner assembly rests at what I’m going to call the “out” position and you have to push it to the “in” position to allow the plate to bolt down.
Both the other times I’ve done this service, it has worked this way. I did this new clutch hub and it worked this way. After realizing something was wrong with the install, I undid the work and retraced my steps to check if it was my error or defective parts, and I was putting the stock setup back into the bike and found that I was unable to push the pusher back into the shaft. It was stuck solid in the out position and no amount of force could move it. What I ended up trying was to take off the front sprocket cover on the opposite side to release the pressure on that inner assembly. This did allow me to push the pusher back in and did not require constant pressure to get the clutch assembly fully torqued down. I then reinstalled the front sprocket cover with the rod into the slave cylinder as it should be. I tested this and everything operates correctly.
A few days later I received some parts to hopefully make the new inner hub work, so I repeated the install procedure for these new parts and at the end when I needed to install the pressure plate I again had the same issue of not being able to push the pusher back in. I repeated the steps I took in the previous paragraph and it all worked out the same way. Unfortunately the new parts I received still did not fix the issue I was having with the new hub. So I undid the install again and went back to the stock parts. I had the issue with the pusher again this time, but once everything is back together it all operates correctly.
So after all this, my question is I know that entire clutch pusher assembly from slave across to the pressure plate should move in and out when you put pressure against the pusher on the clutch side. Why is mine not allowing this to happen? Anyone ever had this issue? Should I be concerned? Everything works just fine when I do the job with the extra step of removing the sprocket cover so I’m really not understanding what my issue is. The only thing I can possibly think is some sort of issue with the slave cylinder. I did have issues with my original slave that was on my bike from the factory, so I swapped over the slave that came on this new motor.
Any ideas or input would be appreciated. Thanks!
What I want to talk about in this thread is another issue I have run into while performing this modification.
I have done the clutch in the Busa twice now, and I know that when I’ve done it in the past, when installing the pressure plate you need to hold pressure against what Suzuki calls the “pusher”. This is the small steel piece with a flange that the clutch rod pushes when you pull the lever. This inner assembly rests at what I’m going to call the “out” position and you have to push it to the “in” position to allow the plate to bolt down.
Both the other times I’ve done this service, it has worked this way. I did this new clutch hub and it worked this way. After realizing something was wrong with the install, I undid the work and retraced my steps to check if it was my error or defective parts, and I was putting the stock setup back into the bike and found that I was unable to push the pusher back into the shaft. It was stuck solid in the out position and no amount of force could move it. What I ended up trying was to take off the front sprocket cover on the opposite side to release the pressure on that inner assembly. This did allow me to push the pusher back in and did not require constant pressure to get the clutch assembly fully torqued down. I then reinstalled the front sprocket cover with the rod into the slave cylinder as it should be. I tested this and everything operates correctly.
A few days later I received some parts to hopefully make the new inner hub work, so I repeated the install procedure for these new parts and at the end when I needed to install the pressure plate I again had the same issue of not being able to push the pusher back in. I repeated the steps I took in the previous paragraph and it all worked out the same way. Unfortunately the new parts I received still did not fix the issue I was having with the new hub. So I undid the install again and went back to the stock parts. I had the issue with the pusher again this time, but once everything is back together it all operates correctly.
So after all this, my question is I know that entire clutch pusher assembly from slave across to the pressure plate should move in and out when you put pressure against the pusher on the clutch side. Why is mine not allowing this to happen? Anyone ever had this issue? Should I be concerned? Everything works just fine when I do the job with the extra step of removing the sprocket cover so I’m really not understanding what my issue is. The only thing I can possibly think is some sort of issue with the slave cylinder. I did have issues with my original slave that was on my bike from the factory, so I swapped over the slave that came on this new motor.
Any ideas or input would be appreciated. Thanks!
