Removing hydraulic clutch rods and ball

Yogi

Yogi

Hero member
Location
Bellingen NSW Australia
Trying to remove both clutch actuating rods and 0.25” ball from hydraulic clutch on OR600 - same principle as my 1200. I can only get one rod out using magnet, the ball and other rod refuse to come out. It may well be that ball has ‘welded’ itself to inner rod. Any ideas on how I can get them both out?
 
Yogi said:
Trying to remove both clutch actuating rods and 0.25” ball from hydraulic clutch on OR600 - same principle as my 1200. I can only get one rod out using magnet, the ball and other rod refuse to come out. It may well be that ball has ‘welded’ itself to inner rod. Any ideas on how I can get them both out?
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Take the clutch off and use something to push it through. I used a straightened out wire coat hanger on the RGS recently clutch rods
 
yep - only way if it does not come out with the magnet is to remove the clutch basket and clutch, remove the square metal and pull it out to the left or push it through with something else.

Once you have done that, take a look at the square block that gets pushed by the rods against the clutch to actually separate it for wear. if it is worn or massively bent, it's best to replace it.

Don't use normal grease on the actuation rods. they are normally meant to be oiled by the oil-steam/oil of the gearbox. doesn't alway work very good and I am not sure what the japs have done differently to avoid that problem, but maybe some very low friction bearing grease (just a dip!) on the ball between the rods could help - not sure.

Also check the rods. If the ball has welded itself to one of the rods, you need to remove any material from that end of the rod and potentially have to harden it again. Maybe best to replace them with new ones. OCT or Wolfgang should be able to sort you out.
 
Many thanks to Paul, Paul and Lothar. After talking with a local guru, it turned out that the real issue was stuck clutch plates. Put front wheel up against a wall pulled clutch in and put it into second gear. Stalled the first time, freed up on second attempt. Leant something new...
 
Puh - I would never use that kind of treatment - not sure what happens to the gearbox teeth... :eek:

I can only recommend to use an engine-cleaner and warm the bike properly up. if you can find a looooong road with no traffic lights, just go for a ride and pull clutch while breaking on the rear and pulling throttle open. It will free up soon, too, but with no harm for the gearbox.

on your bike, Yogi, I would recommend using the engine cleaner to make sure the sticky material on the clutch gets removed. I used this in the past with good success:

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you can also use Motul's equivalent:

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thanks Paul, must admit I never worked on an Atlas (even only once sat on one...). Ball bearing would be a real improvement over the 3 cylinder...
 
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