So does bike momentarily lurch forward with a massive CLUNK!! when you normally engage first gear? Also, was rear wheel revolving on the paddock stand in first gear with clutch lever pulled in?
Yeah, I think there is an issue with how much it engages and disengages. The pressure plate will travel quite far if the lever is set to the widest span. Need to do some more testing.
But if you can select first easily with clutch pulled in then you can cross "clutch binding" off the list which is a step forward. Pulling clutch lever further in won't cause any more binding (or have the effect of reducing revs/stalling) unless you have something wrong with your clutch pushrod or the pushrod bearing is distorted or seized (which is still a possibility).
Just an update, I haven’t had chance to check the rod but I did take the bike for a decent ride. Still cutting out 50% of the time when pulling in the clutch when coming to a stop. Noticing clutch moan now, my idle is strong(2k) until I rev, then it drops(1200-1000) will climb back up shortly after. I have another odd one, with the bike off the side stand upright the idle is good, I pitch it over to the left and the idle increases, pitch it right and the start to drop. Tank is full and no cables are being pulled.
did you inspect rod and bearing? also what you said made me think of a bearing behind the clutch assembly, very rarely wears or fails.
Not yet, should have some time tomorrow to inspect them. I will look at the schematics for the clutch an look at checking that bearing aswell. cheers
it does still sound a bit like a pushrod problem, at worst extreme pushrod can become two pieces (splits at failed bearing) and still work. I think the majority of owners would twig before this happened..
Just took the plate and rod out, I’m guessing the big seal is supposed to be inside the slave cylinder?
That seal sits in a recess in the slave cylinder body (item 27) but is not difficult to get out and can stick to the engine casing. It must have done that and then came off when you pulled out the rod?
Does look like as above, The main thing is that it looks like bearings and pushrod are okay so another one to cross off the list. You could check play of clutch gear (17 above) while you are there.
Just been out again, not sure if that is from the slave cylinder, there is no room for it to come through(hole is too small) I took a couple of pictures of the effect the lever span has on the travel of the clutch. Top is with the lever all the way out, bottom is close to the bars.
yes, you can, I haven't managed to find any YouTube videos yet to help access play, I know there are several but this was around 10 years ago - it's unusual but worth checking. The main one that fitted symptoms was pushrod fail/partial seizing so can at least move on from that.
not sure what you mean re: - hole too small. regarding pictures and your notes:- do you mean the other way round? You only need around 2 mm of pressure plate movement for clutch to work correctly, looks about ok, and operation while starting, selecting gear and moving off will confirm.
The seal is from inside the clutch end of the gearbox shaft. The push rod must have been pulled out from the clutch side and pulled the seal out with it. It is item #30 in this pic from the parts list.
