Clutch problem

[Ted]

At the beginning of September had to fit a new clutch to my 1150GSA, had been slipping for some time and it looked like oil contamination (stain on gearbox/engine joint). Sure enough the gear box seal had gone and the gearbox was covered in oil. So cleaned it all up new clutch fitted and seal, rebuild and all fine.
Done about a 1000 miles and last week on way back from Blackpool to Manchester clutch started to slip under acceleration.
Just removed the box again and found the clutch drive plate oil soaked but no sign of any leaks inside the gearbox housing is dry, flywheel and engine case seems dry and no fan splatter pattern on the drive plate. Attached pictures show as it came apart not cleaned anything. Did notice about an eggcup full of oil drop out when the clutch slave cyl removed, don’t remember that much before, and the seal I replaced on the gearbox input shaft is at 4mm deep should be 5mm but no sign of it leaking. Can oil run up the clutch push rod on to the plate? Any ideas or suggestions before I order a new plate and seal may be the push rod felt as well.
May be a coincidence but the last time the clutch started to slip was on the same trip never going to Blackpool again

 

[Colban]

Have heard stories of clutch fluid migrating along the pushrod tube and contaminating the friction plate,but the felt seal is supposed to stop that.
Possibly the slave cylinder seal has blown and the slave needs replacing.
When was the last time the clutch was bled and did you notice any black bits in the fluid or having to top up the resevoir?.

 

[Steptoe]

Have heard stories of clutch fluid migrating along the pushrod tube and contaminating the friction plate,but the felt seal is supposed to stop that.
.

I don't think the felt seal is used as a stand alone seal. It maybe more of a damper to silence the pushrod rattling in the input shaft tunnel.

But thats the most likely where the contamination has entered the clutch housing

 

[Ted]

Thanks guys I will replace the felt seal. The clutch fluid seems ok, not low or dirty, the contamination is definitely oil not clutch/brake fluid. Is there a seal at the slave cyl end of the push rod? or is it a new cylinder I need. What stops the oil going down the push rod tube? Just don't want to take the box out again and need it to be reliable for day to day and another biggish trip in the new year.
Once again thanks for the info

 

[Big Jets]

Ted i had the same prob with my mates R 1150 R .It was the seal behind the slave cylinder.Replaced it and the little felt wrapround thingy and the bikes been sound since.Imfairly certain thats your problem.

 

[Ted]

Ted i had the same prob with my mates R 1150 R .It was the seal behind the slave cylinder.Replaced it and the little felt wrapround thingy and the bikes been sound since.Imfairly certain thats your problem.

Sounds like the problem. Can you change the seal without stripping the box? just hook it out and tap in the new one.

 

[beermonster]

Mine went last year, it was the slave cylinder, the felt seal did provide some respite but gave up in the end. Fluid did eventually make it past the seal and knackered the clutch. You may well find that the clutch fluid level has dropped.

I ended up replacing the slave cylinder, about £60.00 I think as it was the safer option, don't think you can rebuild it anyway. While your at it you might want to look at clutch hose, especially the connection at the slave cylinder end as mine was corroded, Steptoe has posted about the problem.

Simon.

 

[pomm001]

Ted
if the plate is contaminated what does it smell like ?
gear oils tend to have 'amines' which make them smell a bit fishy
brake fluid smells different ?

 

[Engineer]

I don't think the felt seal is used as a stand alone seal. It maybe more of a damper to silence the pushrod rattling in the input shaft tunnel.

But thats the most likely where the contamination has entered the clutch housing

Aren't felt seals used to filter out the dust and dirt from the main seals?

 

[Ted]

Mine went last year, it was the slave cylinder, the felt seal did provide some respite but gave up in the end. Fluid did eventually make it past the seal and knackered the clutch. You may well find that the clutch fluid level has dropped.

I ended up replacing the slave cylinder, about £60.00 I think as it was the safer option, don't think you can rebuild it anyway. While your at it you might want to look at clutch hose, especially the connection at the slave cylinder end as mine was corroded, Steptoe has posted about the problem.

Simon.

Cylinder is fine, the plate is oily and smells of gear oil. The seal on the shaft at the slave cyl end is proving a pig to get out, its 38mm deep and can't get at it to pull it out. Got the Claymer manual and it just shows it pushed out from the inside (split the box) then tapped home from the outside again.
Any suggestions as to how to get it out without splitting the box or damaging the case/ gear shaft.

Thanks.

 

[beermonster]

Seal

Ted

I had that seal replaced as a precaution, whilst the box was out, the Haynes talked about dislodging it by using a screw driver/punch on one side of the seal. I tried but got nowhere as I was concerned I might just push the seal down too far and be unable to retrieve the thing. I ended up taking the gearbox to an independent (RGM) and he bashed straight through it with a sharpened dowel and just pulled it out. Simple really but as I had never removed one before I would not have done that.

Simon

 

[bigchris]

all this talk about knackered 1150's is making me feel glad I bought a 1200

 

[Ted]

All done and dusted. Thanks for the replys. Found out that the seals have been modified. You can spot the latest ones as they are brown not black so replaced both with the new type.

bigchris
It's not knackerd its just resting