Clutch/clutch rod problem

[wildwilly]

Hi, folks. I'm a new member (joined last night). My inquiry concerns something that I couldn't find here on a search. Perhaps one of you has had experience with this. I am the second owner of an '97 R1100R, bought in 1997 with 1500 miles on it. The bike now has 59000 miles on the odo.

At 42000 miles I began experiencing a situation where it became necessary to adjust the clutch cable freeplay frequently. Occasionally, I would check it prior to the first ride of the day, and it might require slackening, or shortening; not consistently, one way , or the other. Finally, I was riding home from my work and the clutch lever became ineffective to shift gears. I ended up blowing through several stop signs (very rural area) and made it home in third gear.

I ended up having to slowly disassemble the bike, checking in stages for the problem source. Apparently, I was not able to extract the clutch rod until I had removed the transmission. The clutch rod was stubbornly stuck within the engine output drive shaft. The grease/lube had solidified, preventing easy extraction of the rod.

I inspected the rod, throw-out bearing, and clutch/transmission splines. Everything appeared to be, what I consider, normal wear for mileage/age. I installed a new rod (which was made one-piece, different from the original), throw-out bearing, clutch cable, clutch friction plate, and the neutral switch. The clutch and shaft splines were greased, and I had Brattin Motors replace the input shaft seal on the final drive. Since then, I've accumulated 17000 miles with no problems. I appologize for the length of this thread. But your input on this matter would be greatly appreciated.

[jdiaz]

Shouldn't the region of the clutch pushrod receive splash lubrication from the transmission gearbox oil? Strange.

[MCMXCIVRS]

Shouldn't the region of the clutch pushrod receive splash lubrication from the transmission gearbox oil? Strange.

Negative, it passes clean through the shaft. If oil could get in there, it would have to be sealed somehow to keep it from pouring out onto the clutch.

[BubbaZanetti]

i've heard many tell me that the pushrod was a real bear to get out, practically slid out on mine without touching it, i would think a tight fit would affect smooth travel

[MCMXCIVRS]

When reassembled, the pushrod really only needs lube at the ends where it contacts the clutch pressure plate and the actuator. The pushrod does not contact the inner diameter of the shaft and so grease in there would only serve to create the situation you have experienced.

[RiverRat280]

You need to put a little lube on the felt sleeve on the pushrod and that rides on the inner part of the shaft. When I pulled mine out I had to be real carefull not to bend it pulling the tranny only to realize later after pulling the slave cyl. I can pull the pushrod from the rear of the tranny.

[bmwmick]

I inspected the rod, throw-out bearing, and clutch/transmission splines. Everything appeared to be, what I consider, normal wear for mileage/age. I installed a new rod (which was made one-piece, different from the original), throw-out bearing, clutch cable, clutch friction plate, and the neutral switch. The clutch and shaft splines were greased, and I had Brattin Motors replace the input shaft seal on the final drive. Since then, I've accumulated 17000 miles with no problems. I appologize for the length of this thread. But your input on this matter would be greatly appreciated.

Willy,
Look closely at the throwout bearing (piston) for damage. Your symptom sounds like it could have been caused by that too. As long as the housing is not damaged, the bearing good it's probably OK.