Folks, im working on the mid engine BEC project with a GSXR 1100 WP engine and tried to drive it in my road today (private road officer). I got it into 1st gear and with my foot on the clutch it jumped forward and stalled. I cant get it out of first gear...any idea what it could be?

Does anyone here have a mid engine BEC that could take a pic of the gear selector lever at the engine end so i can compare?

I guess you should have a hydraulic clutch.


Hope I'm not stating the obvious.
Is the clutch moving the rod the actuates the clutch.

I have got some down loaded PDF GSXR1100W and RF900RR manuals if any use.

I dont think its anything to do with gear selection but clutch set up.
Give the clutch a good bleed, had something similar while ago.
And BEC's do jerk forward a bit.

quote:

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Originally posted by rf900rush
I guess you should have a hydraulic clutch.


Hope I'm not stating the obvious.
Is the clutch moving the rod the actuates the clutch.

I have got some down loaded PDF GSXR1100W and RF900RR manuals if any use.

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Just seen that I've managed to bend the gear linkage rod!! Is this an easy repair???

Is this a big/expensive repair?

This was it before

its a weedy little thing that, make a new'n rather than repair. if you dont have the facilities any metal shop could make one.

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Originally posted by maccmike
its a weedy little thing that, make a new'n rather than repair. if you dont have the facilities any metal shop could make one.

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when i initially looked at the picture i thought it looked like a cable. but a cable set up needs 2 cables to push and pull. so i figured it must be a rod?
your cockpit view picture - the mechanism at the engine end is different to the before and after photo's.
the more i look at it it does look like a cable within a rod.
without seeing its operation i cant figure out how it would push.
im writing - looking at pictures - writing etc.
think iv figured it out. it is a cable but runs inside a tube that would allow it to work both ways, cant imagine its efficient though.
your choices are;
add a second cable to pull from the other side, then you've got two pulling cables.
repair what you've got. - the sleeve needs pushing back towards the large nut and maybe a couple of spot welds.
replace what you've got.
change it completely with a rod mechanism.
where you based?

think id change it to a rod, wouldnt be hard at all, if you were to do it yourself you'd only need an angle grinder and a cheap welder plus materials like stright thick walled tubing, tap and die set, clevis pins, split pins etc. would need to floor mount your lever though.

ill take some pictures of mine tomorrow, very simple set up. easy to replicate.

The pics were taken 8 hours apart! Like you say, it looks like a 4/5mm cable within a sheath......i dont get how it can push? The way its routed from the cockpit is to much of an angle for it to be a rod.

Im in Aylesbury, Bucks.

Maybe because the sleeve is away from the nut there is slack which wont allow the gear change?

quote:

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Originally posted by maccmike
ill take some pictures of mine tomorrow, very simple set up. easy to replicate.

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By the looks of it the lever was floor mounted before

Looking at your pictures theres plenty of room to rod it. you'll see when i take pictures tom.

Cheers mate, i realy appreciate it. just found a pic of the original set up

yes something like that.

and you've already got the floor bracket.
shame your so far away

I will take a close look at your pics tomorrow and see if I'm
Capable of doing it.

Cheers once again for your help

Iv not forgotten you mate, its raining and my car's an outdoor car. if it stops before the grand prix ill take pictures, if not it'll be this afternoon. hope thats ok.

That's fine mate. It's nice and sunny down here at the moment...no doubt that will soon change!

http://www.locostbuilders.co.uk/photos.php?action=showphoto&photo=2DSCF4585.JPG

I dont know how you upload pictures like you have done so done it this way instead ^^^^
Its still raining so drawn the setup
at each end of the horizontal rod is an adjustable clevis pin and pin.
rod passes through the fire wall and onto the gear selector splined lever.
it really is a simple set up.
I will take pictures of it for you though when I can
Mike

Cheers for the pic mate. The reason they used a cable last time was due to the exhaust...in my engine bay, the exhaust is where the rod would have to go through...look to the left where the orange cable is...theres the hole through the firewall where the cable came throough



however, next to it is another hole...in this pic its above the orange cable. It runs a few cm above the floor pan clears the exhaust



I could run the rod through that just above the floor. Using the blue cable it appears to go straight to where my old shifter was. I can either try and buy/make/move the floor mounted box to that location and do as you say or put back my old shifter and use another wire?

mine actually has a second pivot point behind the wall because of a similar reason. the rod could be dog legged?
the other option is to run a second cable, ill upload another drawing

http://www.locostbuilders.co.uk/photos.php?action=showphoto&photo=DSCF4584.JPG

the blue is your current cable starting from below the gear lever bracket
the green is the second starting from above the lever bracket.
that might be the easier option.
rip the old one out and start again as its damaged anyway.
couple of suitably long handbrake cables and sheaths will work a treat.
do you weld?

Im loving the hand drawn pics

Nope..ive not tried welding yet...its on my list of things to do. My brother welds so if needs be i can get him over to mine.

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[Edited on 30/7/12 by maccmike]

there you go mate
not pretty I know, Im in the middle of tarting up.
1st = shows rod off bottom of gear lever passing through bulk head to bell crank.
2 = bell crank behind bulk head.
3 = bell crank to splined selector lever at gearbox end.
the bell crank is to dog leg the rod as one of the exhaust headers is in the way but today Im going to remove the bell crank and have a fixed dog leg.
After all this I do think you'd be better off with twin cables.
I look forward to seeing it at some point...

Cheers for all your help mate. I will let you know what i go for...im thinking with the layout it might be easier to replace like for like....ill have a think about it and let you know

No worries mate, this is what I did today, works perfect.

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[Edited on 30/7/12 by maccmike]

That looks like something that could work on mine! are the angles welded?

yeah all welded, cost me £5. its solid, probably went bit ott really. doesnt need to be that strong as changes gear easily so not much strain on it. and maintanence free.

Right...the update.

The new control cable arrived today and ive installed it....but ive got the same problem. I can get it into 1st. Sometimes it stalls even with the clutch pressed. Sometimes it doesnt. When it doesnt i can drive it in 1st, stop but cant get it out of first gear back to N unless i turn the engine off and rock the entire car back and forth, then i can select N

I reckon its either a knackered slave cylinder...or maybe a dodgy seal etc (ive stripped, cleaned, bled, new fluids etc already), Or the clutch plates are not disengaging. Its not a spring clutch, its a diaphragm clutch. ive tried adjusting the foot pedal in case it wasnt set up right but alas no luck

Any thoughts wise ones?

N1

[Edited on 7/8/12 by number-1]

If the bike engine has been lying a while the clutch plates can stick.
It sounds like this could be the problem with yours.

If you jack up the car (and chock the front wheels!) put the car in gear, foot hard on the clutch, start the car and keeping your foot on the clutch try accelerating and braking at the same time [do you have 3 feet ]

This can sometimes unstick the plates.

Failing that take off the clutch cover and pull all the plates and steels, lubricate and reassemble.

haha i need another foot! I took the clutch cover off today and its a diaphragm clutch. I tried to take it apart but the 50mm nut spolied that idea as i didnt have an impact gun or clutch tool! I reckon the plates are sticking. Ive got it booked into a garage over the weekend to sort the clutch out and set the engine up. Im searching for a trailer at late notice.....the seacrh continues

how you getting on?

Hello mate. The car went into DWR racing for an engine tune and clutch replacement. With the new cable I had the same issue. New clutch will sort it. Should get it back mid week so will update you with the result.