Stuck Clutch on an Airhead:

[Voyager]

Hi,

My next door neighbour has, amongst others things, a 1984 R80GS PD. It has around 20,000 miles on it and doesn't get much use.

He went to take it out yesterday but the clutch wouldn't free-up.

I wasn't there, but have suggested:

1. Putting it in gear, holding in the clutch and rocking the bike backwards & forwards.

2. Putting it in gear, holding in the clutch and trying the starter (He thinks it won't do this due to an interlock) - I think my 1989 100GS allows you to start in gear with the clutch in (but I need to check) - my 2003 K1200GT certainly works like that.

3. Run it down a hill in neutral, hold in the clutch & hack it into second - I wouldn't recommend that as an approach but thought I had better mention it !

4. Remove the gearbox, identify why the clutch has stuck and fix it (the least-likely option to be considered !).

Anyone got any better ideas ?

Many thanks.

Bob.

 

[Steptoe]

I alway put the bike against a brick wall, and with the engine running stick it into gear -

never failed yet

 

[Voyager]

I alway put the bike against a brick wall, and with the engine running stick it into gear - never failed yet

Thanks . . Neighbour Tom certainly got it running, then put it in gear - but it repeatedly stalled the engine (I probably should have mentioned that).

I guess he wasn't using many revs . . Would you recommend fast tickover / 1500 rpm or more ? Seems a bit brutal on the gearbox

Bob.

 

[(RIP) Proff]

Had same prob with my 90s once.
Started it, let it tick over , roll down hill and slipped it into gear[ O' the skills of driving crash gearbox lorries in my past }
Opened her up gently, clutchless changes up till I was in 4th and then held clutch in and opened her up against stop, went from 30 to 80 in v quick time and clutch freed off, had to remember to throttle off quickly tho, didn't want valves and pistons getting too well acquainted
Also did same on mates R45, but that was so gutless it took 5 attempts before succeeding...

 

[Voyager]

Thanks for the advice guys, all much as I thought (having been there with a 350 AJS in the 60s).

However - Why do they stick ?

My suspicion is oil on the plate or corrosion on the splined shaft. I suppose rust on the flywheel would also cause it.

Has anyone taken one apart afterwards and identified the cause ?

Should we be planning to strip the gearbox out ?

Ta.

Bob.

 

[Ogmios]

Should we be planning to strip the gearbox out ?
.

i'd look at / drench in WD40 (and repeat and repeat !) the pushrod assembly first. - relatively easy to get at / you might be lucky.

keep us posted

 

[spot]

I had a similar problem with an r100/7 years ago. I bumped started it and the clutch freed of. Never had another problem with it.

 

[Pukmeister]

You could always try removing the starter to get access to the clutch, then give the pressure plate a few smacks with a hammer whilst barring the engine over by hand. It might shock/free up the plates?

 

[Steptoe]

You could always try removing the starter to get access to the clutch, then give the pressure plate a few smacks with a hammer whilst barring the engine over by hand. It might shock/free up the plates?

It's an R80. Thats a non option.

The clutch friction plate surface corrodes, and sticks to the pressure plate and cover plate.

All that happens when you pull the clutch lever is the diaphram spring gets depressed. And thats it. The clutch stays together.

It's an even harder job taking the gearbox out and trying to free it off when it's stuck as a one piece clutch .

 

[thornley]

Is the clutch stuck or has the push rod snapped? The thrust bearing used to give up the ghost and the pushrods were prone to snapping. No matter how hard you pull the clutch in the plates don't seperate. Maybe I'm getting confused and the later airheads had the modified thrust bearing and push rod. My earlier R100 RS 1979 suffered from this and I thought the clutch plates had stuck. Possibility?.. and easy to check by removing the actuator arm and withdrawing the push rod. Getting late the brain's in sleep mode

 

[Voyager]

Thanks Guys - The clutch is now free.

Put the bike on the centre stand, started the engine, snicked it into second / third, revved it up and applied the back brake with the clutch out.

Seemed to do the trick.

All components seem OK.

I suggested that Tom use it more to avoid a repeat !

Time will tell.

 

[Harry Nicholson]

If you are not going to use the bike frequently put a small wedge bertween the clutch actuating arm & the frame . You need to pull in the handlebar lever before you fit the wedge .

Harry

 

[AberdeenAngus]

Stand back - thread resurrection in progress....... shazam !


Pal of mine has a 94 R100GS PD and he's just had the opposite problem with his clutch - the pushrod is sticking in.
Complete engine rebuild last year. Been stood best part of a year with only occassional use.
Cable and lever operation are normal weight but can feel 'rough' when pulling clutch in.
It's def. something going on in the casing as he can see the casing lever relax and the pushrod staying in..
He says that if he waits a while the pushrod eventually comes out. and may then work normally for a while before sticking in again.

Wondered if anyone had any light to throw before we start ripping things apart.

 

[abrasion]

sounds like the plastic plunger / bearing sticking in the gearbox case , ive had it a couple of times.
Easy to cure just clean and lube everything.

 

[MattW]

Might be better off asking this in the airhead section...

 

[AberdeenAngus]

Might be better off asking this in the airhead section...

Oh bugger, sorry. Just went on the thread title. Didn't realise.

 

[John Roberts]

Have you considered the possibility of the cable sticking, or perhaps the clutch lever- unlikely, I know, but easily checked.

 

[DrFarkoff]

And then I'd come down there and Flog yer skinny ass !!!!

WD40 Fish Piss!!!

If you aren;t using the bike (and its not in the Dining room out of the inclement weather like mine is) Pull the clutch lever in and stick a small wooden wedge in as close to the adjusting bolt as you can (takes the pressure off the arm) You only need a few mm to relieve the pressure

i'd look at / drench in WD40 (and repeat and repeat !) the pushrod assembly first. - relatively easy to get at / you might be lucky.

keep us posted

 

[AberdeenAngus]

Nope, not the cable or lever. You can see the plunger sticking in. He's going to try giving it a splurge of something slippy and cleaning as best he can before he starts stripping box.