Clutch lever won't pull after clutch pack change?

[emasen]

Hi All,
Beginning to get desperate. Recently at dealer for 38000 service, mentioned clutch bite point issues from hot to cold as now getting dangerous also mentioned difficulty in selecting neutral and clonky gearchange at times.
Came back to collect, service done but no result on the clutch issues, he commented that if it persists I would be looking at a full clutch replacement...

200km ride home and no real difference to the clutch issues, bite point still wildly variable, especially when hot.

Decided to replace the clutch to see if it would solve any of the problems. U tubed it to see was I up to it ,got the parts and away we go last night.

Followed the directions removed all parts, no visible damage to clutch basket... perfect. Pressure plate a little scored on the friction surface so replaced that. Removed all the spacers and discs in order and replaced them in the same order, refitted new pressure plate,springs and bolts no problems.

Went to test the clutch operation was OK...... PROBLEM..... clutch lever now wont pull.

Back again, removed everything back to empty basket thinking something had been caught preventing it working. Tried again, Clutch Lever still wont pull. Clutch lever operation was perfect before I started....

Where do I go next, what am I looking for, did I miss out on some stage of this job...... help appreciated.

 

[autogs]

Don't want to be harsh but,why wade in with a clutch replacement, varing bite point etc leads me to think it could be hydraulic prob or if it's an early bike a pushrod problem,early bikes had several probs with pushrods fluid levels and even the odd gearbox fault, the clutch you took out showed up as ok,the not working points to a pushrod prob, have you the right parts?
Unfortunately this is prob a fault you have introduced, if you had to resort to you tube you prob should have left it alone.

Sent from my SM-A202F using Tapatalk

 

[Bem]

IIR the clutch push rod comes in three parts, so some care and precision on reassembly is required - have you read the instructions/seen the vids on the Recluse site? And on other youtubers sites?
And assuming you get it back and working then change to 10/40 oil for a small improvement.

 

[emasen]

Don't want to be harsh but,why wade in with a clutch replacement, varing bite point etc leads me to think it could be hydraulic prob or if it's an early bike a pushrod problem,early bikes had several probs with pushrods fluid levels and even the odd gearbox fault, the clutch you took out showed up as ok,the not working points to a pushrod prob, have you the right parts?
Unfortunately this is prob a fault you have introduced, if you had to resort to you tube you prob should have left it alone.

Sent from my SM-A202F using Tapatalk

Replaced clutch on the advise of the main dealer.
1st BMW Gs so checked to make sure I wasn't taking on more than I could handle with something I hadn't worked on before.
Hyd and fluid checks were done by dealer and he assured me all working as they should and bike was tested by technician.
All recalls had been done including longer pushrod issue.

I'm like you and reckon on a hydraulic issue on the clutch, maybe master or slave cylinder BUT servicemanager in main dealer says no, hence clutch pressure plate and clutch plates to remove 3 items that may cause the issues.

 

[emasen]

IIR the clutch push rod comes in three parts, so some care and precision on reassembly is required - have you read the instructions/seen the vids on the Recluse site? And on other youtubers sites?
And assuming you get it back and working then change to 10/40 oil for a small improvement.

Yes, watched the recluse video, very informative. TBH it was an easy job so far.
On the pushrods. the only one that comes out is the last small one that was upgraded on a previous recall. When the clutch lever is pulled I expected that to move.... my clutch lever is not engaging so it currently not possible to see movement.
On the 10/40 oil..... fully synt or otherwise?

 

[Winjar]

If I can remember exist different size pushrods.

 

[David makkai]

Hello , did you find a fix for your issue ?

 

[PitaNaanRoti]

Hi All,
Beginning to get desperate. Recently at dealer for 38000 service, mentioned clutch bite point issues from hot to cold as now getting dangerous also mentioned difficulty in selecting neutral and clonky gearchange at times.
Came back to collect, service done but no result on the clutch issues, he commented that if it persists I would be looking at a full clutch replacement...

200km ride home and no real difference to the clutch issues, bite point still wildly variable, especially when hot.

Decided to replace the clutch to see if it would solve any of the problems. U tubed it to see was I up to it ,got the parts and away we go last night.

Followed the directions removed all parts, no visible damage to clutch basket... perfect. Pressure plate a little scored on the friction surface so replaced that. Removed all the spacers and discs in order and replaced them in the same order, refitted new pressure plate,springs and bolts no problems.

Went to test the clutch operation was OK...... PROBLEM..... clutch lever now wont pull.

Back again, removed everything back to empty basket thinking something had been caught preventing it working. Tried again, Clutch Lever still wont pull. Clutch lever operation was perfect before I started....

Where do I go next, what am I looking for, did I miss out on some stage of this job...... help appreciated.

You haven’t fitted the pressure plate correctly.
There’s a second “clack” as you turn it into place where it’s located.
Takes a small amount of extra pressure to get it located properly.
Caught me out the first time I did one.
It’s absolutely nothing to do with any of the above “suggestions “.