Ok, I have a 96 YZF-600. I was installing my new clutch hub and was tightening the big nut in the center (1 1/16"???).

I noticed as I turned it that the hub spins as well. So I attempted to Jamb the clutch hub using a screw driver. I put the screw driver into the grooves and jambed it against the outer basket.

I began tightening the nut and it got tighter and tighter, but wouldnt finally stop. Eventually I heard a snap sound!.

Im not sure what I broke. I cannot find any broken metal pieces. Please tell me how I was supposed to tighten that nut, and gimme some insight as to what I broke/how to get in there to fix/find it.

gnusnu

i reassemled everything and found that I have no clutch lever tension. Not sure if this is related.

Hey there, I can only assume that the screwdriver end or whatever you had it locked against is what is broken.I put my hub together with an impact gun because I didn't want to buy the correct tool.I would only recomend this method if you are experienced with air tools because you can easily ruin your month by snapping the shaft or worse.Did the hub free spin when you heard the noise?Maybe it just broke loose and did not damage anything.If your new to mechanics them I suggest that you buy the clutch holding tool and torque wrench to do the job.May be cheaper or same price to have local bike garage do the job after you have to buy tools.P.s. Electric impact works good and will not produce enough torque to break anything.Also make sure all spacers/washers are located properly according to Yamaha parts illustration.This job only took me 15 mins with the impact on my 99 r6 and still works good two months later.

im actually a subaru technician, however, this is a bike, thus my lack of experience is showing thru.

I realize the size of this nut and the type of threads being used, it HAS to be tight. I was using the correct socket and a 1/2 wrench w/ a relatively small handle. I know I didnt produce enough torque to snap anything.

What I think you dont understand is:
The clutch pack was not in when I started to tighten down the nut. I was trying to think of a way to keep the hub from spinning free. So I stuck a screw driver thru the outter part (is it called a basket?) then I jambed it into one of the teeth on the hub. I will try to get pictures later.

As I tightened down the nut on the hub, it got tighter and tighter, but It didnt seem to get to a good tight point. So I kept going just a bit further, using only my hand on the middle of the wrench. Finally I hear a snap.

I inspected the tip of the screw driver, its there. The Teeth on the hub are also there.

I couldnt find any debris. I have no clue what snapped. I reassembled eveyrthing and found that when i put the clutch pack in, i am able to tighten the nut w/o jambing anything. Just putting it into gear.

After its all assembled, i notice i have no tension on the Clutch Cable. I removed the clutch cable housing on the opposing side of the tranny. I see how the cable operates. it is wrapped around an essentric hub thing. As you pull the cable, the essentric-hub undwinds and pushes on a pin that goes into the transmission. I assume this pin disenguages the clutch. I tried pressing on this pin manually, and I cannot get it to move in, or out. There is no springy-ness to it like i assume there should be.

If you can reply to me, add me to AIM: Unsung Boxer. I would also LOVE diagrams if anyone has them. I need to know more how this operates.

And yes, I am a tech. I do have proper tools, but i F'd this up ;) So feel free to speak to me in Technical terms, i just assumed most of you guys are DIY'ers.

-Jake

see following pictures.

This is what it looked like when I installed everything. Notice the clutch pack is not in.
http://img194.echo.cx/img194/1192/16qi.jpg

Here is the nut I need to tighten. The hub was spinning, so I had to come up w/ a way to hold the hub still:
http://img194.echo.cx/img194/8779/31ai.jpg

I attempted to jamb the hub againts the basket using a screw driver. When I tightened the nut, I heard a snap.
http://img194.echo.cx/img194/9265/27rx1.jpg


After this, I hear the snap. I tried to install everything. When I got it together I had no tension on my clutch cable. Something broke, but what?

on further inspection:

The clutch cable spins an essentric hub, that forces a 3 pins into eachother thru the center of the transmission.

I dont know what these pins are called. The pin forces the bearing and pressure plate on the other side to disenguage.

Nothing is wrong w/ the pins, nothing is wrong w/ the clutch lever or cable, and nothing is wrong w/ the essentric hub. However, the pin does not reach the bearing on the other side to disenguage the clutch.

What the heck?!???!

Here you can see the lack of travel in the pin.
http://img148.echo.cx/img148/4254/clutchproblem3ii.jpg

The Pin doesnt move far enough to reach the bearing on the pressure plate, there for the clutch will not disenguage when assembled.
http://img99.echo.cx/img99/418/cluthcproblem27as.jpg

Ive looked over the parts to make sure they are correct and installed properly. I cannot see why the is sitting so low, and has such little movement. BTW.. the clutch cable is adjusted out as far as it goes.

finally found a diagram.. turns out i was missing the ballbearing in the pins that move the pressure plate, doh! Oh well, it wasnt my fault.

I found the bearing in the oil pan and reassembled it all. She runs!