Weird Dowel in center of Clutch

[sfrligo]

Hi! New here, so thanks for any help.

I am changing the clutch plate on my 1994 k75. Got to taking the transmission off, but there was this long rod coming out through the middle of the clutch that wasn't in any of the videos or schematics I've looked at: any idea what it is? it runs straight into the transmission spline, from beyond the clutch.

It made sliding the transmission back near impossible: kept hitting the ABS or frame to clear the length of that rod.

Any ideas why it's there? how to work around it?

Thanks!

[sfrligo]

no idea why that image loaded upside down: it's right side up on my phone and computer. Apologies.

[552255]

...Clutch pushrod I think.  why or how it is removed/stayed put is for someone else to say. good luck!

[sfrligo]

thanks! It could well be the pushrod: but the ones I've seen in videos are 3-4 inches long. This is closer to 9. It means that even when taking the transmission off with 4" dowels, there was still plenty of this rod to pull back off of...

[sfrligo]

Thanks, 552255, it certainly is the pushrod.

Does anyone have any ideas as to why it stayed lodged in the clutch or how to rectify the situation?

[koapono]

it is the clutch pushrod and it should pull right out with minimal effort, at least it does on my K100 can't imagine the 75 is much different.
it bends easily so be careful when you start applying force.
is there any lateral, side-to-side movement? if so just keep wiggling and pulling it straight back, if bent it will likely need replacing for proper assembly and clutch activation.
g'luck

[Motorhobo]

It's the clutch pushrod, #1 here in the first diagram.

When in place it is seated within the bore in the in the diaphragm spring #3 in second diagram. Like kaopano said, once you've pulled back the transmission back a couple inches, you should be able to get your fingers in there and pull the pushrod back so it retracts into the transmission where it will reside while you remove the transmission from the bell housing. If it didn't come out of the clutchpack and is stuck, it's possible that the clutch diaphram spring shifted somehow during the installation of the clutchpack and is now pinching the pushrod so it won't slide out easily. If the spring is not centered properly and is pinching the pushrod, it might affect the balance of the clutchpack and result excess vibration on rotation. At any rate, I think if you remove the six bolts that hold the clutchpack together, the whole thing will pop off and the pushrod will become unpinched and will likewise fall out. Be careful not to bend it if it's not already bent.

If like kaopano mentioned you put any pressure on it while removing the transmission, the pushrod may be bent. You mentioned that the ABS got in the way because you had to pull the transmission all the way back off the still-seated pushrod. I don't know how you'd get the transmission off anyway with the ABS units still on. When I pull the transmission, I've always had to remove everything that might obstruct the transmission on removal, that includes both ABS modulators, which can be tied up to the frame with bungees other such methods along with the footpeg plates and calipers without disconnecting the brake lines. You have to remove the battery tray mount, which also includes the mounting arms for the ABS modulators, to get the transmission out, so the ABS units have to come off those mounts anyway, no?

Anyway, on reassembly, the pushrod lives in the transmission. When you put the transmission back on, you line up with pushrod end with the hole into which it gets seated, and push the transmission on that way. Don't suffer needlessly -- read this before reassembling.

http://www.motobrick.com/index.php/topic,7086.msg48744.html#msg48744

[Mongrel]

Yep, normally that's in the transmission. Somehow yours got stuck.

[Scott_]

I've also been told that the pushrod on the K75's only install in the transmission from the front input shaft....... you cannot install it from the rear like on the later 1100's.

So don't put the transmission in place with out it in there or you will be doing it again.

[rbm]

Right Scott.  The earlier pushrods had the lip near the tip (see picture below):



This lip prevents the rod from pushing back through the transmission input shaft but also inhibits it from being installed unless the transmission is off the bike.

Later design had the lip at the rear of the pushrod, as shown in the drawing earlier in this thread, allowing the pushrod to be inserted from the rear of the transmission while still on the bike.  There was also a redesign in the traveller thrust bearing (part #2 above) that the actuator arm road upon on later K100s, from 3 separate pieces to one enclosed plastic piece.