Results 1 to 13 of 13

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

  1. #1
    Registered User Manitou_Commando's Avatar
    Join Date
    Mar 2008
    Location
    Manitou Springs, CO
    Posts
    88

    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
    Join Date
    Mar 2010
    Location
    Vancouver, B.C. Canada
    Posts
    1,996
    Diaphragm spring backwards?
    MJM - BeeCeeBeemers Motorcycle Club Vancouver B.C.
    '81 R80G/S, '82 R100RS, '00 R1100RT

  3. #3
    Administrator 20774's Avatar
    Join Date
    Sep 2005
    Location
    San Antonio, TX
    Posts
    13,363
    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
    Join Date
    Mar 2008
    Location
    Manitou Springs, CO
    Posts
    88
    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
    Join Date
    Jun 2011
    Location
    N.E. Ohio
    Posts
    426
    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
    Join Date
    Mar 2008
    Location
    Manitou Springs, CO
    Posts
    88
    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

  7. #7
    Registered User PAS's Avatar
    Join Date
    Jun 2011
    Location
    N.E. Ohio
    Posts
    426
    There is a seal that presses into the end of the input shaft if there wasnt oil would migrate forward onto the clutch disk. Item 16 on the diagram. I doubt this is your problem
    seal-2.jpg

  8. #8
    Registered User
    Join Date
    Jan 2006
    Location
    Wisconsin and Florida
    Posts
    376
    " I actuated the clutch lever once and to my surprise, the pushrod stayed IN,"

    It would be helpful to know if you felt near normal resistance as the clutch lever was pulled that first time or if the lever and pushrod just moved it without much resistance.

    The idea is to know if the clutch spring was compressed by the lever movement after assembly and has not released

    or

    If the clutch spring was compressed by improper assembly

    or

    if the difference in thickness of the new clutch requires much different cable adjustment - I don't see where you mention cable adjustment

  9. #9
    Benchwrenching PGlaves's Avatar
    Join Date
    Oct 2003
    Location
    "Big Bend" TX
    Posts
    8,770
    Loosen the transmission mounting bolts (just loosen - not remove) and wiggle the trnsmission a little. I suspect the nose of the clutch rod is stuck (binding) in the crankshaft pilot hole.
    Paul Glaves - "Big Bend", Texas U.S.A
    "The greatest challenge to any thinker is stating the problem in a way that will allow a solution." - Bertrand Russell
    http://www.bigbend.net/users/glaves

  10. #10
    Registered User PAS's Avatar
    Join Date
    Jun 2011
    Location
    N.E. Ohio
    Posts
    426
    Quote Originally Posted by PGlaves View Post
    Loosen the transmission mounting bolts (just loosen - not remove) and wiggle the trnsmission a little. I suspect the nose of the clutch rod is stuck (binding) in the crankshaft pilot hole.
    If I recall correctly a service bulletin recommended the center hole of the clutch spring to be lubed.

  11. #11
    Registered User Manitou_Commando's Avatar
    Join Date
    Mar 2008
    Location
    Manitou Springs, CO
    Posts
    88
    Many terrific and thoughtful comments.

    The pressure plate was installed in reverse position. All better now.

    New rebuild on the gearbox from Matthew Parkhouse and new clutch. Ran great today. Thanks.
    Adios, Amigos.
    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

  12. #12
    Registered User festes's Avatar
    Join Date
    Aug 2006
    Location
    Waldorf, MD
    Posts
    37
    I hate when that happens. Glad all is well now.

    Mark

  13. #13
    Registered User PAS's Avatar
    Join Date
    Jun 2011
    Location
    N.E. Ohio
    Posts
    426
    We all have and will make mistakes! Glad you found the issue.

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •