Clutch problem R80GS Basic

[Mad Hatter]

Went out on my new to me R80GS Basic this morning but only got 5 miles before I had a clutch problem. Basically the clutch jammed with the lever pulled in and wouldn’t re-engage drive from the motor when I released the lever. The cable isn’t broken and the lever actuation arm was moving ok. It felt like the clutch wasn’t sliding back along the shaft and re-engaging. I ended up pushing it for about a mile and then it started working again when it cooled down, but the clutch release was ‘sticky’.

Any suggestions?

 

[mikeyboy]

Clutch release bearing has prob swelled and is binding in its bore,if it’s the later plastic type.
Or could be corrosion on the pushrod inside the input shaft.
Bad news is you will have to pull the swinging arm out to get the push rod out for a looksee.
Worst case scenario is if the bore that the pushrod moves in is f###,
Then you are into a gearbox rebuild.

 

[B Murr]

The plastic bearing in mine swelled a bit a d I was getting a very stiff clutch when the bike had warmed up. I took the bearing off and sanded it down a bit to slightly reduce the diameter and that seems to have sorted it. I don't think the swing arm needed to be removed to just check tbe bearing but the actuator arm had to come off and I recall it being a fiddly little space to work in.

 

[mikeyboy]

The plastic bearing in mine swelled a bit a d I was getting a very stiff clutch when the bike had warmed up. I took the bearing off and sanded it down a bit to slightly reduce the diameter and that seems to have sorted it. I don't think the swing arm needed to be removed to just check tbe bearing but the actuator arm had to come off and I recall it being a fiddly little space to work in.

Correct,
But the arm has to come out,or pulled out of the way to get the push rod out

 

[Mad Hatter]

Thanks Mikey. The bike has been laid up for 20 years and only just been recommissioned. Can I get at just the release bearing without pulling the swingarm?

 

[Mad Hatter]

Thanks B Murr, you answered my question!

 

[Mad Hatter]

Thanks to both of you for the advice. I’ll have a look at it tomorrow night.

 

[Mad Hatter]

Just looking at the parts diagram, once I’ve pulled the actuating arm off and the rubber bellows, and the spring, can I just pull the piston (release bearing) out by hand to inspect it, or does it need a puller?

 

[Gelandestrasse]

Maybe a lot of use might bring it back into line?

 

[B Murr]

Just looking at the parts diagram, once I’ve pulled the actuating arm off and the rubber bellows, and the spring, can I just pull the piston (release bearing) out by hand to inspect it, or does it need a puller?

You can pull it out. I will not have had a specific tool to use, probably used a narrow nosed pliers but could just as easily have resorted to a bent piece of wire or something such as that but I can't remember exactly what it was.

 

[SteveHop]

Mine used to stick like .
There is an aricle by "snowbum" where he quotes the correct size of the plastic bush.
I just took mine out and machined the bush down to reduce the diameter , never been a problem since then,
Its to do with the moisture absorbtion characteristics of Polyamide , in otherwords it absorbes moisture and swells.

 

[SteveHop]

Mine used to stick like .
There is an aricle by "snowbum" where he quotes the correct size of the plastic bush.
I just took mine out and machined the bush down to reduce the diameter , never been a problem since then,
Its to do with the moisture absorbtion characteristics of Polyamide , in otherwords it absorbes moisture and swells.

He gives a max diameter of 28.5mm so you should aim for just under that say 28.4mm

 

[Mad Hatter]

Great, thanks for all the advice gents. I’ll let you know how it goes ��

 

[B Murr]

Great, thanks for all the advice gents. I’ll let you know how it goes ��

Its compulsory that in receipt of the sage advice from this forum that such operations are carried out with a video camera ( 1980's VHS or SVHS allowed) of some description taped to your forehead and share the results for our delectation( is that a word?)

 

[Kenny]

Be careful you don't damage the clutch arm rubber boot....have you seen the price of those things !! Oh and if it has not been run for 'X' amount of years, I'd take out the clutch pushrod and clean/grease it up as well.

 

[F8GS]

Can you not take it back to the place you brought it from and get them to sort it?


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[Mad Hatter]

I can and the seller has offered to fix it and/or supply parts FOC, so I’ve no complaints there, but it’s actually easier for me to do it��

 

[DrFarkoff]

Just remember if you are going to be pulling and hauling at this

Tie the centre stand forward to the front wheel so you don't knock the bike forward off the stand

Removing the battery and maybe the battery tray seeing its freshly rebuilt will let you see the thing better (But its still a fiddle in from below and the side to do the work!!)

 

[Mad Hatter]

Thanks, good tip re the stand!

 

[Bubb]

Check that it’s not the needle rollers in the arm pivot....mine eventually gave up, and once replaced all was fine. Easy fix compared to having to pull the arm out

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