Major fxxx up!

[phatngo]

Guys, I was following this thread to try and diagnose a weird gear/clutch grinding noise http://gstwins.com/gsboard/index.php?topic=20468.0

At the point where I needed to release the nut on the 'Clutch Mechanism Release Adjustment screw', the screw broke in two as I was releasing the nut!!!

I put everything back, and to my dismay, the clutch will no longer engage with first gear! I'm guessing that screw has made all the difference and that unless I can somehow remove the broken one and replace it, I'm 'screwed'?

Any help/advice would be greatly appreciated. I'm 7 weeks new into bike world, and may have bitten off more than I can chew. Before I call a mechanic to pick her up and fix her, was trying a last resort to fix her.

Cheers

[Watcher]

If there's any part of that screw still sticking out, see if you can grab it with some pliers and turn it until it comes all the way out.  I don't think that screw has much resistance on it, it should turn easily.

If it broke off inside, you will need a screw extractor.  They look kind of like drills but they twist a little differently.  You first drill a pilot hole into the broken screw, hammer in the extractor, then when you turn the extractor the broken screw comes out with it.


But before you get that far, see if you can upload some pictures to clarify the situation.

[mwe]

Im having a hard time picturing what you did or how you broke that screw (my guess is that you didnt release the lock nut and that is why you broke the screw).  I dont think that the adjustment screw is under much tension (with the locknut removed/released) and even if it were for some reason, the act of braking the bolt may have released whatever stress was on it.  I would cross your fingers and go get a set of dental picks (any picks) and some penetrating oil and delicately see if you can grab an edge on the surface and back the screw out.  otherwise...I am not sure what the procedure would be to try and retrieve it from the other side.

[mwe]

I would not go trying to use an extractor on that thing.  Their utility is questionable in most circumstances and I would definitely a left handed drill bit before the extractor.  the last thing you want to do is brake an extractor.

[sledge]

Try and drill it out if you want but then what?

The whole part is f%&ked, you may as well get a new one and just replace it 

[phatngo]

Cheers lads. I'll try and post a pic later when I get back from work. Based on that pic from SLEDGE, the screw in the middle has broken off. I might buy a new part, what's the name of that part Sledge? So I can order one.

I'll see if I can remove the screw later, and if that's the only problem, maybe I can just replace that and go through the tensioning process again. Fun and games. The bike is fine otherwise, absolutely love it. Was gutted I couldn't take it for a spin yesterday after my gaffe!

[phatngo]

On second look, it's not as bad as I thought, although I'll have to wait til I get home after work to have a proper look. Seems only half of the end tip of the screw has chipped off, so there should be enough for me to grab onto with a pair of pliers and unscrew. Can't seem to attach a photo as the file size is too big.

After much searching, I've managed to find a supplier in Sydney we has the right screw and nut in stock so picking them up tomorrow. Once I've replaced them I'll go through the whole process again and let you know how I get on, and hopefully I can get rid of that annoying grinding noise when I pull out of first gear.

[sledge]

The screw is part no 09134-06010 and the nut is 08310-00067.

If the screw does come out without damage to the other parts there is no need to replace the whole component. You MUST loosen the nut before trying to get the screw out.

[phatngo]

Cheers Sledge. Should be picking up both today then hopefully go through the adjustment process successfully this time!

I actually pulled out that push rod and it doesn't seem to go back in very far. Any idea how many centimetres it's meant to stick out? Seems like it won't go in any further but in my head it was originally further in than it is.

[phatngo]

Cheers for the advice guys. I got a new screw and nut, and managed to get the old one out fine. I've adjusted everything and it all seems to run fine. I still get this clunk as I pull away in first gear, which I now think is a wider problem, and sadly might have to send her in for a clutch/gear check, as no amount of clutch adjustment has managed to solve the problem.