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Thread: New clutch resulting in un-diagnosed "issue."

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  1. #1
    Registered User Manitou_Commando's Avatar
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    New clutch resulting in un-diagnosed "issue."

    The gearbox for the R100 RS was rebuilt last month with five new bearing, all new seals and the circlip upgrade. Rear main seal and all that were replaced last year so I have some experience taking apart and reassembling the flywheel, clutch, and gearbox.
    A new clutch arrived last Saturday and rather than doing something domestic, I undertook the assembly. It progressed in much the same way as it has for me previously. Once the clutch cable was reattached, I actuated the clutch lever once and to my surprise, the pushrod stayed IN, never releasing. BTW, there were no extra parts left over after it went back together.
    Whadayathink I will find when I take it all apart tomorrow? This will be yet another learning opportunity
    .
    Rick

    It ain't what you don't know that gets you into trouble. It's what you know for sure that just ain't so. A. Lincoln

  2. #2
    Day Dreaming ... happy wanderer's Avatar
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    Diaphragm spring backwards?
    MJM - BeeCeeBeemers Motorcycle Club Vancouver B.C.
    '81 R80G/S, '82 R100RS, '00 R1100RT

  3. #3
    Administrator 20774's Avatar
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    Assuming you know the orientation of all the clutch parts, I would have the say the problem is the clutch pushrod. If the felt on the pushrod became dislodged, it could be wedged between the rod and the tunnel through the transmission. The diaphragm spring has quite a bit of pressure behind it, but if the felt were wedged, it's possible it could prevent the rod from returning.
    Kurt -- Forum Administrator ---> Resources and Links Thread <---
    '78 R100/7 & '69 R69S & '52 R25/2
    mine-ineye-deatheah-pielayah-jooa-kalayus. oolah-minane-hay-meeriah-kal-oyus-algay-a-thaykin', buddy!

  4. #4
    Registered User Manitou_Commando's Avatar
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    I know (?-HA!) that I used the schematic for clutch assembly with the pressure plate in first, followed by front
    carrier, friction plate and rear carrier. In my model there is no felt washer to put in incorrectly. I have done this a few times and this is what baffles me - that since I have successfully done this in the past, I should be off the hook from making mistakes.

    Anyway, I will get out there and report back to the group on my stupid mistake once it's discovered.

    Plausible deniability will be searched for as well: The gnomes did it.

    Rick
    Rick

    It ain't what you don't know that gets you into trouble. It's what you know for sure that just ain't so. A. Lincoln

  5. #5
    Registered User PAS's Avatar
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    What year? I would remove the linkage for the push rod and see if you could pull it out. If it's an 81 or newer you have a small seal in the end of the input shaft that keeps oil from escaping around the push rod. Look at it also.

  6. #6
    Registered User Manitou_Commando's Avatar
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    It's an '88 R100 RS. I did remove the pushrod. All seals are new, as noted earlier. Oil dose circulate clear to the rear end of the pushrod, as this lubricates the bearing at the aft-most site of the rod. A rubber boot seals that oil from the environment.
    Rick

    It ain't what you don't know that gets you into trouble. It's what you know for sure that just ain't so. A. Lincoln

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