Please advise: When attempting ot remove the clutch push rod from the clutch side, I can pull it so far and then it appears to stick. I then used a copper mallet from alternator side to push it further against resistance, up to where it disappears into enters the crank case, then again attempted to pull, quite hard from the clutch side, but it is snagging somehow. As I haven't dismantled one before, I though I'd ask for advice, in case of causing damage. Haynes merely say remove push rod by pulling it out. Cheers, John
It sounds like the pushrod is either damaged or even bent. Early pushrods used to break and only the later modified pushrod is now sold by a dealer. You could try drifting it out from the alternator\sprocket side using a good drift that is slightly smaller in diameter than the shaft size. If you do this I would be careful not to tap it too hard in case further damage is caused. Normally the shaft pulls out very easily and I have never had a problem with one. I have however seen a bent pushrod on a TZ Yamaha cause a problem and that had to be drifted out gently to remove it, this bike uses the same type of setup as a Ducati. If the bike has been crashed or knocked then it is possible that the rod could become bent and this might be why the rod is sticking. The other possibility is galling on the shaft which is not allowing the shaft to pull out smoothly.
Ah, great information, thanks. I do suspect galling on the shaft. I'll proceed to drift it out gently now. John
If the shaft does have galling on it, I would suggest running a small drift through the shaft hole a few times to dislodge anything such as debris or metal filings that may remain in the area (hole) in which the shaft runs. Make sure the shaft moves in and out cleanly and without snagging on anything. Possibly lightly oil the shaft when you put it back.
Sure thing Red, thanks. Actually I'll be splitting the cases, because I have a gallery plug backing out, so I can make a very thorough inspection after dismantling.
I drifted the pushrod out OK, with some amount of firm taps from copper mallet. Its condition is OK. The galling is in fact not chafing, but the thickest, stickiest concoction ever, of grease and what I presume is clutch dust. The mainshaft needle bearings will be cleaned out somehow before re-assembly. I wondered, what is your advice for lubricating the pushrod - engine oil? Some kind of grease - copper or lithium: OR, a combination of suitable grease at the tips, and engine oil along the length?
The pushrod, as far as I remember, is lubricated by engine oil, therefore I would just oil the rod after a good clean and slide it back. I seem to remember there are small oil holes in the gear shaft to allow for lubrication of the rod. I lubricate the mushroom head that bears on the clutch release with coppaslip.
thanks for that. Then, knowing what the sticky stuff in there is like, I'm a little concerned that such lubricating holes may well be blocked, i'll have to check that when splitting (waiting for a hydraulic puller now for gear), by soaking and using brake cleaner i reckon.
