Issues reinstalling 2006 R6 Clutch Cover!

[WinVT]

Ok, so I just completed the slipper clutch mod to my 2006 r6. Got the clutch put back together, tightened the spring bolts and am set to put the cover on....

Took a minute to get the clutch rod puller to line up with the clutch cover, but finally got that to stick and everything seemed fine. I played with the clutch arm at the bottom of the cover while I had the cover hand pressed against the case and it seemed fine. It moved/returned just like normal. The dots were a little off mark, but I know how to adjust that once the cover is completely on. So here's the issue....

With everything in place, I tightened down all of the clutch cover bolts. I go to hook up the cable, and the clutch arm is frozen. It is very difficult to move and it is so tight that the spring does not have enough force to return it. If I hook up the clutch cable and pull the clutch lever, it will pull the clutch arm forward and then stop in place due to the resistance.

I'm sure it is something stupid, but what did I do wrong here?? I took it apart and tried it again and I got the exact same result. It seems to be fine when the cover is being hand held against the case, but once it's tight it locks up on me. I'm tightening the clutch cover bolts to spec, and everything in the clutch is tightened to spec....

Any clue what I might be doing wrong here?

[Degsy]

Wirelessly posted

I think you have your pressure plate on incorrectly. It has to lone up a certain way if I recall. It's an easy mistake to make.

[WinVT]

Ok, i'll take a look at that, but I made sure to line up everything while putting it back together.... I suppose I could have missed it.

[csmutty]

No idea man. Wish you were closer.

[WinVT]

No worries, Degsy was right on. Took it back apart and sure enough the pressure plate was improperly installed. Looks like I lined it up with the wrong marker, causing it to seat improperly. Works perfectly now.

Degsy, thanks for the quick and accurate response! Really appreciate it!

And Christian, i'll let you know if it all works... i've got my fingers crossed, just gotta put oil in it now.

[csmutty]

I can't wait to hear what you think after the slipper mod.

[Degsy]

Wirelessly posted

Glad to help!
I made the same mistake once on CEOs bike when we were rushing to get his clutch back together for a rave.

[csmutty]

Wirelessly posted

Glad to help!
I made the same mistake once on CEOs bike when we were rushing to get his clutch back together for a rave.

Were you trippin?

[Degsy]

Wirelessly posted

Haha. 'e' s and whizz.

[OreoGaborio]

GLOWSTICKS!!! GLOWSTICKS!!!

[Brendin87]

You're gonna love this! What route did you go with the springs? I've heard a couple different ways of doing this.

[WinVT]

Yeah I saw that you could try a number of different configurations. I went with they style csmutty suggested, which was cut the first two and use them as spacers and then install the third on top.

Unfortunately now my bike won't run! I don't think it has anything to do with the clutch... I also installed an APE cam chain tensioner and I think that has thrown things out of whack. After I put it all back together, it started and ran for about 10 seconds. Then it died and would no longer start. I replaced the APE tensioner with the stock tensioner and still will not start.

Now i've got the thing all stripped down trying to figure out what it might be, but honestly i'm kind of lost...... doesn't make much sense to me. If anyone could shed some light that would be great... but I know i'm not giving you much to go by.

[ecd2004]

is it turning over or does it just not do anything? it isnt the cct, your bike would start it would just rattle like a mofo unless you have it too tight and then i dont even know what would happen

[WinVT]

It is turning over and sounds fairly normal from what I can tell, no odd noises or anything. And there were no strange noises when it first died, although it did sound like it was bogging a little bit.

[ecd2004]

check the vacuum lines, you probably have a pinched fuel vacuum hose or something

[WinVT]

Well I pulled the airbox and injected fuel directly into the throttle bodies with no luck. I would assume this would rule out a fuel issue. Tomorrow i'm going to check spark based on a mechanics advice, but I can't help thinking it has something to do with the cam chain. I just hope I didn't throw the timing out of whack... but I don't feel like that would have really been possible.

[Degsy]

Wirelessly posted

It is entirely possible to throw the timing off if you turned the crank at all with the tensioner out. I doubt you did this though.

[darkduc7]

+1 I'm with degsy I doubt this is timing related. It wouldn't have ran at all or you would have heard bad noises. I would go towards electrical, pull the plugs...check for spark, ect. It could just be a coincidence something broke while you were doing maintenance.

[WinVT]

Ok thanks guys, worked on it first thing this morning and we are not getting spark. Well that opens a whole lot of potential issues.... any suggestions on where to start? Just strange that it ran for a little bit when we put it all together and then suddenly lost ability to spark....

[WinVT]

Ok sorry, scratch that, bike DOES get spark, does get fuel, just won't quite fire. Sounds like it is right on the verge but never gets there.

[freeskier]

timeing sounds like the issue. if you wiggled the cam while the chain was off it could have done it

[WinVT]

timing is off, checking to see if we have any bent valves.

[WinVT]

update:

checked the valves, they were fine. set the timing, reinstalled the APE cam chain tensioner making sure to keep timing lined up. bike fired right up! and no more cam chain rattle! looks like i'll be able to race next week!

[Degsy]

Wirelessly posted

You turned the crank backwards, didn't you?

[WinVT]

No, I made sure to always rotate clockwise, but I think I may have rotated before there was any real tension on the chain while installing the ape tensioner. Maybe that would have been enough to throw it off?