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Author Topic: Lower Clutch Lever End Hitting Exhaust  (Read 12507 times)

Offline TaosBrick

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Lower Clutch Lever End Hitting Exhaust
« on: July 24, 2013, 11:33:14 AM »
Wuz messing with my clutch adjustment the other day. I can only screw the adjustment bolt on the lower lever in none too far before the end that holds the clutch cable barrel hits the exhaust upon releasing the clutch. That just can't be right - observations?
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Offline motodude

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Re: Lower Clutch Lever End Hitting Exhaust
« Reply #1 on: July 24, 2013, 11:51:28 AM »
There is a spec for the distance the lever is from where the cable comes through the frame.  I want to say 65mm but don't quote me on that.

There are several write-ups on adjusting that lever.  Here, and at ibmwr.org.

When properly adjusted, it comes close to the exhaust but should not touch.

Tom
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Offline Grim

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Re: Lower Clutch Lever End Hitting Exhaust
« Reply #2 on: July 24, 2013, 01:09:01 PM »
Chris Harris has a video on YouTube. The adjustment on the cable at the lever should leave 3 in of cable from the housing to the cable end. The 5mm of play is suppose to be adjusted with the bolt and jam nut NOT the adjustment on lever on the handle bars.
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Offline TaosBrick

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Lower Clutch Lever End Hitting Exhaust
« Reply #3 on: July 24, 2013, 01:52:18 PM »
Hmm... Seems odd that there should be gobs of adjustment still left on that bolt when the end of the lever is touching the exhaust. Doesn't seem to match the Teutonic precision that I have noticed on all other aspects of the machine that I have examined.
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Flog It Every Day - I mean, the BIKE!
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Offline Grim

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Re: Lower Clutch Lever End Hitting Exhaust
« Reply #4 on: July 24, 2013, 03:32:00 PM »
Here is the video. If you run out of adjustment something is wrong. I recall you had some down shift issues after a lube. Did you take the bearing out that the clutch lever pushes on?


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Offline wmax351

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Re: Lower Clutch Lever End Hitting Exhaust
« Reply #5 on: July 25, 2013, 06:22:26 PM »
If you run out of adjustment, your clutch is worn. By time I replaced mine, you really didn't need the bolt for anything other than a seal. In fact, when I lost the bolt once (fell out), I replaced it temporarily with a 1mm undersized bolt with the proper thread pitch just barely inserted. 
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  • Albuquerque, NM
  • 91 BMW K75 Standard, 98 Moto Guzzi California EV
Bikes:
Current:1991 BMW K75 Standard, 1998 Moto Guzzi California EV11
Past: '83 BMW R65LS, '75 Honda CB550F, '69 Honda CB175, 1999 Royal Enfield Bullet 500, 1973 Triumph Tiger TR7V, 1971 BMW R75/5 in Toaster outfit, 1979 Harley Davidson XLS-1000 Sportster Roadster

Offline TimTyler

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Re: Lower Clutch Lever End Hitting Exhaust
« Reply #6 on: July 26, 2013, 12:03:50 AM »
You should be able to adjust the lever-to-muffler distance using the screw and locknut on the hand lever. Then adjust the screw that depresses the clutch push rod, ideally with some free play.

If you can't do that, you'll need a new clutch disc.
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Offline TaosBrick

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Lower Clutch Lever End Hitting Exhaust
« Reply #7 on: July 30, 2013, 05:26:24 PM »
Ok, Clutch adjusted to spec, 3" between end of cable housing and barrel-end - check. Use bolt and locknut on clutch arm to adjust for 5mm play at handle - check.
  End of clutch arm no longer hitting exhaust, in fact, nearly 1cm of clearance.
  However, am still experiencing hard downshifting, particularly from 5 to 4. In all other respects, clutch appears to be working as it should. When held in while bike not in motion, no drag or lurch when shifting from neutral to first, or with any other gear.
  Scratching head...
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Flog It Every Day - I mean, the BIKE!
'92 K75, '73 R75/5 Café,'89 Yam XT350
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Offline mystic red

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Re: Lower Clutch Lever End Hitting Exhaust
« Reply #8 on: July 30, 2013, 05:52:26 PM »
Recent spline lube?
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Offline TaosBrick

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Lower Clutch Lever End Hitting Exhaust
« Reply #9 on: July 30, 2013, 06:48:15 PM »
Splines lubed no more than 8,000 miles ago, in early May.
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Flog It Every Day - I mean, the BIKE!
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Offline johnny

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Re: Lower Clutch Lever End Hitting Exhaust
« Reply #10 on: July 30, 2013, 07:26:02 PM »
if it were me this is what I would do...

in 6th gear... ignition off... on grade between 12 and 18%... sit on moto facing backwards...hands swept back on grips... pull in clutch with right hand... commence to rolling backwards down hill...

pop the clutch at approx 40mph spinning the drivetrain backwards... slowly roll to a stop... be careful cause its tricky to maitain balance below 5mph...

do not start it... push it up the hill and repeat to total of 3 efforts... drink some mead...

j o

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Offline motodude

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Re: Lower Clutch Lever End Hitting Exhaust
« Reply #11 on: July 30, 2013, 07:32:37 PM »
Quote from: johnny on July 30, 2013, 07:26:02 PM
if it were me this is what I would do...

in 6th gear... ignition off... on grade between 12 and 18%... sit on moto facing backwards...hands swept back on grips... pull in clutch with right hand... commence to rolling backwards down hill...

pop the clutch at approx 40mph spinning the drivetrain backwards... slowly roll to a stop... be careful cause its tricky to maitain balance below 5mph...

do not start it... push it up the hill and repeat to total of 3 efforts... drink some mead...

j o

...and, you could probably charge admission!

Seriously, depending on how hard the downshift is, I would either live with it until winter or tear it apart [now] and figure out what is wrong.  If the latter, I would pay attention to the clutch "pressure plate" spring.  Is it square when sitting on the bench?  Is it the correct height?  And, of course, are the input splines [still] well lubed.

Tom
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'90 K75RT
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No, I am not cool.  Yes, it really is the journey.

Offline TaosBrick

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Lower Clutch Lever End Hitting Exhaust
« Reply #12 on: July 31, 2013, 10:58:15 AM »
...drink some mead.

How'd u know I was workin' at a renfest right now j o?

Oh yeah, I posted it 😜
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Flog It Every Day - I mean, the BIKE!
'92 K75, '73 R75/5 Café,'89 Yam XT350
Expect Nothing, Be Ready For Anything.
- Samurai Maxim

Offline wmax351

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Re: Lower Clutch Lever End Hitting Exhaust
« Reply #13 on: July 31, 2013, 01:59:23 PM »
http://www.honeyrun.com/


If you would like some excellent mead, this is my close friend's family business.
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  • Albuquerque, NM
  • 91 BMW K75 Standard, 98 Moto Guzzi California EV
Bikes:
Current:1991 BMW K75 Standard, 1998 Moto Guzzi California EV11
Past: '83 BMW R65LS, '75 Honda CB550F, '69 Honda CB175, 1999 Royal Enfield Bullet 500, 1973 Triumph Tiger TR7V, 1971 BMW R75/5 in Toaster outfit, 1979 Harley Davidson XLS-1000 Sportster Roadster

Offline TaosBrick

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Lower Clutch Lever End Hitting Exhaust
« Reply #14 on: July 31, 2013, 04:55:29 PM »
Betts you didn't know my brick in fact has a sixth gear, johnny.
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Flog It Every Day - I mean, the BIKE!
'92 K75, '73 R75/5 Café,'89 Yam XT350
Expect Nothing, Be Ready For Anything.
- Samurai Maxim

Offline TaosBrick

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Lower Clutch Lever End Hitting Exhaust
« Reply #15 on: August 05, 2013, 05:30:48 PM »
OK, back to the matter at hand, my left hand. Not what your thinking, perverts.

Thinking that 43,000 is a little soon for a clutch to wear out, or is it? I am still pretty new to K-ness.  Observations?
  As I say, it would appear that the drivetrain and engine are fully disengaged from one another when the clutch is engaged.
Sure hope it gets me back to Taos from NY...
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Flog It Every Day - I mean, the BIKE!
'92 K75, '73 R75/5 Café,'89 Yam XT350
Expect Nothing, Be Ready For Anything.
- Samurai Maxim

Offline johnny

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Re: Lower Clutch Lever End Hitting Exhaust
« Reply #16 on: August 05, 2013, 06:09:50 PM »
stop your freaking and commence to riding...

j o
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Offline TaosBrick

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Lower Clutch Lever End Hitting Exhaust
« Reply #17 on: August 06, 2013, 11:57:16 PM »
I has been riding - Lots. A leetle freaking over seeming Unknowable Conundrums is normal in the interests of better Brick health, don'tchya think?
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Flog It Every Day - I mean, the BIKE!
'92 K75, '73 R75/5 Café,'89 Yam XT350
Expect Nothing, Be Ready For Anything.
- Samurai Maxim
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