Clutch problem , slipping

[SJK]

All of the dimensions you have checked look correct compared to my transmission that had no installation problem. 

please can you check one more thing for me....

-Piston measurement #B on my drawing is 211mm
-Puck measurement is 22,5mm
we know as they fit into each other we get a length of 233,5mm

The measurement thru the gearbox from spline to rubber boot clamp area is 220mm

So this is then obvious that the puck will stick out 13,5mm :yow

please can you assemble the Pushrod and Puck into the gearbox(all the way from the front of the Gearbox) and tell me if your puck sticks out as far as mine   

[The Mighty Gryphon]

You are mistaken on where the rod is.  The flange at the forward end of the push rod does not sit against the front end of the transmission input shaft.  It is up against the diaphragm spring in the clutch pack. 

The fact that the end of the rod protrudes at the rear end of the transmission indicates that something at the front end is not allowing the rod to go as far forward as it is supposed to.  There are only two things that can cause that.  The flange stopping on the diaphragm spring, or the end of the rod not going into the end of the output shaft.   Based on personal experience I have a nagging suspicion that the diaphragm spring is installed backwards.  I know that when I did mine I was confused by the photos in the manuals.  As my feeble memory recalls, the installation of the diaphragm spring is counter intuitive and looks wrong when correctly installed.  I could be very wrong here, but at this point it's all I have.

There is nothing else that I can offer.  There is nothing that any of us can see wrong with your parts.  You need to go back and double check your assembly and alignment of the clutch pack.  As per an earlier post, you need to disassemble your clutch and reassemble it with photos for us to look at.

[Laitch]

You need to go back and double check your assembly and alignment of the clutch pack.  As per an earlier post, you need to disassemble your clutch and reassemble it with photos for us to look at.

It is more work SJK but you are doing it for a constructive purpose—to fill our lonely and idle hours and keep us from feeling morose.

[SJK]

  Just fitted everything back but our Puck is persistent, I will now strip everything photo by photo for you guys, hopefully you can spot the problem, just to confirm this Puck is definitely too far out right ??

[The Mighty Gryphon]

Do you have the Clymer manual?  Go to page 185 and look at photo #53.  It's your call on whether to proceed. 

If you have the Haynes Manual it is page 3-7 photo #6.9c.

[SJK]

If you have the Haynes Manual it is page 3-7 photo #6.9c.

I only have a Haynes, but no pictures of Gearbox on page 3-7 , found this on page 100


Is this your reference?

[SJK]

Ok step by step ready, hope this helps

[Filmcamera]

The BMW one is available here and honestly looking at the clutch page the puck looks VERY similarly placed to where yours is...


http://www.motobrick.com/index.php/topic,2252.0.html

[SJK]

The BMW one is available here and honestly looking at the clutch page the puck looks VERY similarly placed to where yours is...


http://www.motobrick.com/index.php/topic,2252.0.html

Thx Filmcamera, I cant open the file is says its damaged, could you maybe send a screen shot of photo of that , pls pls

[Filmcamera]

Here you go

[SJK]

 :2thumbup: Thanks .....that's not too far off from mine

if the Gearbow and everything is assembled , with the cable disconnected, boot off , spring out, Piston/Puck out.....does the Push rod slide in and out a little by hand? or not?

[technostructural]

Hello folks,


I am doing a spline lube on my 89 K75 with the newer puck design and pushrod (same as this one). I am happy to take any measurements or photos if they are needed.


Cheers.

[SJK]

Hi , thanks for the msg. We kinda have tried and measured all there is to be measured, but if you can maybe please confirm the distance your puck sticks out from the gearbox when mounted to the engine . That's without the spring and rubber boot ofc. Thx

[technostructural]

Hello SJK.


I can certainly take this measurement, but it might be a little while before I'll have it back together to do so. I didn't see your request until I pulled the clutch apart!


Would it help if I took this measurement with the transmission out?

[SJK]

No worries, yes thanks I'll wait till you done and gearbox is fitted again

[SJK]

Hi Everyone

Sorry for the silence, I've been working at the problem with the clutch push rod, and have some feedback

So after hitting a MotoBrick wall and no one seeming to know of a resolution to my problem , I decided to order a new clutch in the meantime as the current one was on its way. After installing the new clutch all has magically sorted its way out and all lines up correctly

It was one of my initial Questions whether a worn out clutch could cause the problem I was experiencing ..... I can now confirm

A WORN CLUTCH FRICTION PLATE WILL MAKE THE PUSHROD AND PISTON/PUCK TO STICK OUT FAR BACK


 :2thumbup:

[Filmcamera]

I am glad you fixed your issue - great job.


Thanks for the update - it is always good to add to the general knowledge of the forum.

[technostructural]

Sorry that I was not more timely in getting back to you. My clutch is still apart as I am waiting on parts. I'm glad you've got this resolved, and thank you for clarifying this for posterity.

[SJK]

Pleasure Guys, and thanks to everyone on the forums help, suggestions and putting up with my constant posting  :yes

[Martin]

 :2thumbup:  Good to hear I'm glad the problem was finally solved.
 Regards Martin.