When it rains IT POURS!

[outrage]

So i decided to follow John R's advise and check my sump strainer for blockage in regards to my super hot engine issue. I saw that its best to do with the exhaust off so i removed that but of course one of the bolts snapped in the head. Pics to follow. What methods should i try to get it out? One of the bolts was shorter than the rest and the threads were almost rusted in even though the bolts had been replaced at some stage and a few have possibly been heli coiled.

Next is the clutch. I noticed the oil level seemed to be a bit erratic and i would get major differences by just leaning it slighty. Also the clutch started slipping under load so an investigation was in order. Firstly i saw the gasket was about 1 inch wide with just a couple of small holes at the bottom to let the oil to the window. I think this was a problem giving me incorrect readings causing me to overfill the engine. The gasket was installed with some red gasket sealer which broke away and found its way into the sump strainer. Pics to follow.
I found a small chunk of the clutch basket broken away but it must have been done before as i cant find any sign of it in the sump. Also the clutch springs seem to be rubbing quite a bit on the inside. Is this normal? And the new heavy duty springs i bought are quite a bit longer than the originals so im wondering if they are correct?

Hopefully all the pics come through.

[outrage]

Heres the springs. Also the clutch friction plates seem fine but the steels show signs of wear. I'd be inclined to replace everything for piece of mind but if the frictions are fine the saving a few £ would be nice.

[bobster]

Just use 3 of the uprated springs installed (every other spring) this should stop the clutch slipping and the clutch will Not require a gorilla to pull the lever in!
Try welding a nut onto the snapped off stud as the heat will probably help free it off and will be easier to get a proper feel if the stud is going to snap again.The clutch basket looks a bit worrying as the metal plates could snag on the broken edges, I would either replace the clutch drum or file some chamfers on the damaged area so the metal plates do not snag on the sharp edges.

[callyboy]

Watcha Outrage, i feel your pain. Like bobster says, welding a nut on works. I usually put a slot in the end and use a good screwdriver to undo it. Bit of heat on it wont harm.

Good luck

Pete

[johnr]

change that clutch hub. whatever broke it is probably well in the past. but thats a high stress fast moving part and any imballance or stress fracture in it could result in a catastrophic engine failure. for peace of mind, id put another one in there. bobsters right about the springs, every other one and see how it goes. as for the crud in the strainer, that seems pretty normal, give it a swill out and it'll be ok. get one of them super strong magnets bonded onto your sump plug if you can, should hold any odd bits of swarf out of the way.

[outrage]

Cheers for the feedback. I thought about the bolt and its not important that i have to get it out before running the bike again. The header pipes are easy to remove individually so i could ride it to a place of repair with just 1 bolt and sort it out. Lee down at Steelheart in Kent could sort it for me. Actually i dont remember seeing any copper rings between the header & head. Will have to go look.
The clutch housing only has 4 springs so should i do only 2? Since i added the Hayabusa master cylinder and Pazzo copy levers it feels feather light so i think i will stick all 4 in and see how it is. Also to check if the plates still slip at top end. BUT if i do this it might cause the damaged hub to go KABOOM!. Im currently looking at that almost complete engine on the bay just as a parts bin. Anybody know what a replacement hub would cost?
I wiill keep an eye out for a decent magnet for the sump but all of that stuff in there is munched up gaskets and goo.

Thanks again guys.

M@

[nokatanayet]

hi, it seems the old kat is having a bad time mate,
the broken hub sleeve is the same as the gsx750es etc p/n 2141031304, i have just checked on a web site, this should help you find one a bit easier.
best of luck.Si

[Pop-Kat]

Hub not available from cmsnl, part number is 21410-31304 you could try ringing robinsons, it lists as 78.50euro's so would be about £80 i guess.. If you go 2nd hand then it's the same part in the gsx750es/ef which broadens the search.
The cover gasket appears normal, although you need a new one now, at least they're cheap

[Pop-Kat]

Well, that'll teach me to nip out for a smoke whilst in mid reply, come back finish my post and the info's been posted, haha

[outrage]

OK so i got a full replacement clutch basket/holder & plates. Instead of exchanging bits over i just did a complete swap of the whole unit. The plates in the replacement look in pretty good nic so i threw them in too. I thought about sticking a few extra holes near the bottom of the gasket so the oil can flow better between the window & gasket but i left it.
Strangely enough the springs in the replacement were different to both i had already. The middle one is the different one so i decided to go with that. The HD replacements were way too long to be able get the screw in and i reckon by the time i got them done up they would be fully compressed. With the new heavier springs i can feel the clutch is heavier but only barely.
I also noticed that the whole engine has been apart before and he used that red gasket sealer which is quite brittle and chips off so i cleaned off what i could.