How far does your clutch pushrod stick out?

[Terry Dymond]

I?m more worried about the funny bits that came out of my hole.

Rephrase please

 

[sfcpiet]

I have been planning on pulling the clutch drum off to inspect the clutch. It rattles like blazes, even after I replaced the primary chains and clutch rubbers. It is very noisy when in neutral, with the clutch lever out. When I pull the clutch lever in, it quietens down considerably.

Just imagine you're a Ducati rider, they go nuts if their clutch doesn't rattle!

Reckon you will find the clutch hub loose on the mainshaft, or the splines on the hub worn, or splines in the basket worn, or anti-rattle springs broken/missing, or a bit of everything.  Not much you can do about worn drum splines except replace the drum, both drums and hubs are getting thin on the ground though.  The hub splines can be carefully re-worked if necessary, deep indents can often cause clutch slippage.  The hub can be modified in the manner of 750 hubs by machining a groove and inserting an o-ring in the rear, quietens the hub enormously, but will require renewal of the o-ring every 2 years or so when the rubber loses its tension.  Fitting the anti-rattle springs is fiddly without the special tools, but well worth the effort imho.

piet

 

[Grant]

Load o' shite.  :-*
Throw the anti-rattle springs away, negligible noise difference.
Change to a duplex Iwis primary change for the biggest difference.

 

[sfcpiet]

Agree, the duplex chain makes a huge difference, but doesn't help much if the clutch is knackered.  Besides, if it is rattly, it surely will not fix itself.  Better to do all you can to prolong the life of the individual components, never know if any new stuff will ever turn up.

I'll demonstrate the "negligable" noise difference next time you drop by, Grant.

piet

 

[Grant]

I have a Corsa with, and POP without, thanks.

I would still check if it is shimmed correctly before suspecting worn drums. As I mentioned in my earlier post.
I had a 1200 back in the day. Hell of a racket. Turned out a DPO had omitted one of these shims.

 

[Chappo]

Thanks Piet and Grant, and you too Tezza

Definitely pulling it apart in the near future. I'll report back. I'll need help anyway, so I'll be back.

I took more pictures, and you can see the circular shape of the black bits. I also posted a link to a video, on dropbox.
A small video of me pulling the clutch lever in, and letting it out a few times. You can hear the noise, but video sound mutes it a little.

https://www.dropbox.com/s/krjkxv19897mco5/noise_m.wmv?dl=0

 

[Terry Dymond]

Bloody big matches in Lake Macquarie
That looks a bit like a helicoil gone wrong, nasty!

 

[Laverdalothar]

for me that looks like the rest of the oil-seal sitting between the push rod and the gear shaft (inside the gear shaft where the sprocket is mounted). Not sure though that the "spring" belongs to the same part, I could also imagine it is from a helicoil. but that would mean you have a damaged seat somewhere, which I can't see on the pics...

what sticks at one end of the "spring" - is that a part of a screw? if so, go and look a bit more backwards, as it could be from your footrest plate or something else more on the rear of the bike, being pulled in to the place you found it by the chain... (I understand it right, it was sitting in the mud below the chain, right?

 

[MotoJouni]

I have regularly cleaned and lubricated the ball with molybdenium grease.

 

[Chappo]

for me that looks like the rest of the oil-seal sitting between the push rod and the gear shaft (inside the gear shaft where the sprocket is mounted).

what sticks at one end of the "spring" - is that a part of a screw?

Hi Lothar, I soaked the bit of wire in paint thinners, the black stuff dissolved quickly, and I saw it is two pieces.
I'm thinking it could be a spring from a seal like the one in the photo.

I see there is a seal under a cir-clip in the diagram, I will have another look later today.

 

 

[Chappo]

I had another look at the push rod hole. It appears the seal in the end has fallen apart. I fished two more bits of plastic/rubber out, and the back half of the seal looks wrecked.

Can I remove and replace this seal from this side? It looks like I can.

Thanks.

 

[redax5]

yes, is supposed to be changed from the side you see

there should be a clip that secures it in place as well

 

[Chappo]

Thanks Red, yes, I took the cir-clip out to check the numbers. The seal I took the photo of, to show the spring, is the correct size, so I don't even have to go shopping.

Might be able to stretch it out to a three beer job I reckon.

Thanks again for the info.