83 VT750 Teardown & Rebuild Project (For "Educational" Purposes!)

[keb709]

Uh oh... So I tried to remove the clutch. Tried to put it into high gear as per the manual, and then I heard a snapping noise, and now the shifter pedal stem(I don't know what it's called, the shaft that connects to the actual shifter pedal), doesn't change gears and has a substantial amount of travel. I have the clutch slave removed, was it a mistake to try and change gears without a clutch? I'm worried...

[keb709]

I'm talking about part 11 in this photo

[mattyo]

Originally Posted by keb709

Uh oh... So I tried to remove the clutch. Tried to put it into high gear as per the manual, and then I heard a snapping noise, and now the shifter pedal stem(I don't know what it's called, the shaft that connects to the actual shifter pedal), doesn't change gears and has a substantial amount of travel. I have the clutch slave removed, was it a mistake to try and change gears without a clutch? I'm worried...

You can change gears without the clutch. That's not the problem here.

How much of the crankcase do you have apart? Ie, is the right crankcover off? Is the left crankcover off? I'm asking because it could be be that the gear shifter teeth just slid apart. As in the parts fiche you posted, teeth on #11 and #13 could have separated. Get some pics up!

I wouldn't worry too much about it. I doubt you actually broke anything trying to change gears.

[OHjim]

Originally Posted by keb709

Uh oh... So I tried to remove the clutch. Tried to put it into high gear as per the manual, and then I heard a snapping noise, and now the shifter pedal stem(I don't know what it's called, the shaft that connects to the actual shifter pedal), doesn't change gears and has a substantial amount of travel. I have the clutch slave removed, was it a mistake to try and change gears without a clutch? I'm worried...

I'm not sure I understand the conditions when you heard the snap. Was it when you were trying to loosen the nut to remove the clutch? Or was the clutch already removed and you shifted gears by hand?

And what mattyo asked . . .

[keb709]

Originally Posted by mattyo

How much of the crankcase do you have apart? Ie, is the right crankcover off? Is the left crankcover off? I'm asking because it could be be that the gear shifter teeth just slid apart. As in the parts fiche you posted, teeth on #11 and #13 could have separated. Get some pics up!

I currently have the left and right crankcase covers off, as well as the piston heads. After some research, I think that you may be right. I think the teeth have separated.

The clutch and flywheel have completely stopped any progress, I think I'm just gonna go to my dealer tomorrow and ask them to remove both...

[keb709]

Originally Posted by OHjim

I'm not sure I understand the conditions when you heard the snap. Was it when you were trying to loosen the nut to remove the clutch? Or was the clutch already removed and you shifted gears by hand?

The clutch is still on the engine, I simply tried to change gears by hand, and heard the snap

[mattyo]

Originally Posted by keb709

I currently have the left and right crankcase covers off, as well as the piston heads. After some research, I think that you may be right. I think the teeth have separated.

The clutch and flywheel have completely stopped any progress, I think I'm just gonna go to my dealer tomorrow and ask them to remove both...

So there's a little cover (1.5" in diameter) just underneath and to the right of the gear shifter spindle. That will pop off and you can see if the teeth on the spindle are aligned or not.

For the flywheel, yeah, you'll want an impact wrench for that bolt for sure! Make sure to crank it clockwise! It's threaded the opposite way. righty-loosy and lefty-tighty.

[keb709]

Here's some pictures of what I've got on my hands at the moment:









I believe the chain in this picture(timing chain?) is loose. But that's a problem for another day...

I went to see if the teeth were aligned or not, and before I could even pop of the cap, this thing fell out:



It doesn't look like it's broken off. Is this why I can no longer change gears?

[luisr320]

Don't worry. That's the way it is. That part is pressed into its position by the right engine cover. There's a hole in the cover to match that rod. The other end will match the shifter rod tooth.

[mattyo]

Originally Posted by keb709

I believe the chain in this picture(timing chain?) is loose. But that's a problem for another day...

That's the oil pump chain. It can be a little loose, no worries there.

The timing chains (there are two of them) are the chains hanging out of the cavities by your pistons.

And yeah, that part that fell out, that's what it should look like. Nothing broke. You probably just shook it loose while shifting gears and it popped out of it's seat. No worries there either.

Oh, looks like you already have the flywheel bolt off/loose. Good deal, that thing can be a real PITA.

Good progress! Keep the pics flowing!