Smithabusa Gear Indicator installation questions & Clutch problem ALL FIXED

[Volvi]

Ive received my GI from smithabusa in the States and have a couple of questions before I install from those that are familiar with this unit.

Does one have to get any new gaskets or o rings beforehand? for the clutch basket.

Holding the brake and in gear is it enough to unlock the 30mm nut or does one have to have that special tool?

Does one have to drain the oil before opening clutch hub? or ok on side stand to prevent oil leak?

cheers

[TheShredder]

Ive received my GI from smithabusa in the States and have a couple of questions before I install from those that are familiar with this unit.

Does one have to get any new gaskets or o rings beforehand? for the clutch basket.

Holding the brake and in gear is it enough to unlock the 30mm nut or does one have to have that special tool?

Does one have to drain the oil before opening clutch hub? or ok on side stand to prevent oil leak?

cheers

Ive used the clutch cover gaskets several times with no problems,
I just smear a very thin layer of  type of gasket goo on it  1st.

I've used the tool to hold the basket in place while undoing the nut
But you could also use 2 of the clutch cover bolts & screw them into 2 of the BTL  studs when the clutch hat is removed & place a large screw driver between them & lock it against the motor to stop it turning .
I dont like the idea of forcing nuts against gearboxes (locked up or not)

YOU DONT HAVE TO DRAIN THE OIL  TO DO THIS
Just place on the side stand with the front wheel up on a brick or paver,  lump of 4x2 etc .It just needs a bit more lean angle for the oil to drain away from the cover.

shane

[Volvi]

Thx Shane. Rod and I today worked on installing this unit. Whilst the GI worked I cant say the same for the clutch. After all was done Huston we have a problem. I'll put it to you as I just did to smithabusa in email, see if you can work it out:

Troubleshoot:

Ok lets run this by you, seeing youve probably taken clutch basket in and out more then anyone else I know.

Installed unit today with a friend. Found bit tricky and fiddly on reassembling clutch basket. Kept all clutch ring/disks in order, last one slotting into shallow insert whilst others in deeper side inserts.

All assembled. Warmed bike up first allowing oil into basket. Pulled clutch lever in.........click, click. clickty click kinda noise from clutch basket. 1st gear in GI showing position OK. Slowly release clutch no pull, no go. engine not engaging transmission, same if went up to 2nd gear. Every time clutch lever pulled in same noise and bike wont move forward at all.

Were totally baffled as to why. Were pretty sure we put in every bit in its right place. The clutch plates perhaps moved around in circle as was very fiddly getting them in, but made sure last one was offset to shallower groove.

Any ideas what went wrong, where we might have done something wrong? The noise isnt a mettalic sound almost like woody clicking.

Mine is a '99 model and the Back Torque Limiter welded up as the BTL mod.

Any ideas?

[xhiler8r]

Mate there is a gear that sits behind the basket that engages the box I am guessing you had to remove everything to change the GPS sensor yes I found it quite difficult to get that gear back in place but it wasnt impossible that is the only suggestion i have that something hasnt quite meshed where it was suppose to

Good Luck with the fix and be sure to post up the answer to your dilema

[ROD]

Would they be the last two cogs at rear of everything they did move but i thought they went back in to spot on second atempt as the basket would not go back at first to i noticed the two cogs had moved.

[Maj]

You want to get them right, thats the oil pump drive.

[ROD]

no prob will try and sort something out over weekend we are trying to find someone to come and have a look for us
on the clutch plates there is a little notch on the outside are all these ment to line up as we are not sure if volvi may have let them slip around while he was holding them
thanks for your advise.

[xhiler8r]

guys just a quick note when i did mine I noticed that I couldnt rotate my rear wheel at all and was freaking out that I f****d something up and it was jammed so i pulled the clutch basket off 3 times and replaced it with the same result even in 6th gear it was a damn effort to spin that rear wheel just something you might wanna check to make sure the gears are engaged properly

[Maj]

Look for witness marks on the thrust washers to make sure there back in the same way they came out, oil pump gear also is not symetrical .

[m8ee]

next time do what i did, take digital pics of everything you remove before it comes off. i had a look for the pics for this mod, but i had deleted them when i finished sorry.

[ROD]

yeh thanks m8ee we have full parts list wich show them in order and nothing was put in the wrong spot and nothing mising see how we go tommorow

[DjPete]

something IS missing or put back wrong.
I guarentee that.
What I don't know but will be interesting to hear is the verdict...
Good luck guys...I would be there but I do my hair on Sundays...

[ROD]

ok maybe there is a couple of things we put in up side down

[DjPete]

we ARE only human Rod...
lol

[RaZz0R]

any damage done?