Anyone with gearbox out at the moment?

[Chris_in_BC]

Just looking at my clutch pushrod. Not sure why the ridges, pretty sure they shouldn't be there. Only thing to cause this is the oil seal, although not sure why.
Anyone seen similar?

[Joan]

That's wild! Neither the '83 R65 nor the '91 R100RT clutch rods look anything but smoooooth.

Looks like it's close enough to the outside of the gearbox that it's road grit?   [smiley=idea2.gif]  [smiley=2cents.gif]

What's your gearbox oil look like on the drain plug?

[its_only_me]

Chris I would change that part, either the seal has gone hard and with road grit caused this, or the metal is soft, but a new seal wont seal properly now which could cause further problems.

[Chris_in_BC]

Thank you, lady and gentleman,

I agree re replacing it.  My oil etc has always been clean.  What I am thinking is that last year, I had to have the rear cover off because  the gasket blew out (another story)  But at the time we found that the rear little push rod seal was gibbled. It was replaced. But maybe it had been gibbled a while and the tiny lip spring had been rubbing on the push rod. I was traveling at the time and the fix was quick with only a few hours downtime, to pull the box, open it up and replace, so I didn't look closely at the push rod. Definitely should have been more obsevant.

Possible explanation.

It is actually quite a way inside, There is the rubber boot, then piston, then bearing, then push rod.

Other comment here is be careful pushing the clutch push rod through the gearbox... don't just jam it through, that oil seal with a coil spring lip is not very robust.
Chris

[Rob Valdez 79 R65]

I don't remember what year bike this is, Chris.  Does yours have the felt?  What did it look like?  I would be afraid to think of what the inside of the input shaft looks like.  

I know airhead is working on a box right now.  You might PM him.

[airhead]

Do I hear somebody rattling my cage??
Can't really add anything to what's already been said, looks like either the installer has been a wee bit hamfisted with the rod and mashed the seal, or dirt has got in (dust boot ok and securely fitted?), or the seal has dried and hardened with age (unlikely, would have needed to have not been running for years). Either way, I've seen a few, and none with ridges like that....................yet!!
Whatever, the seal and rod will have to be replaced as neither will be effective now in sealing.

BTW, the box overhaul done today was, at least on the bench, a complete success. Spins sweeeet, changes crisp, the owner took it home to install on his bike ready for a 1000km round trip with the club next weekend..........that's trust for you!! I just have to finish the overhaul I started on my box for the 90 but was interrupted when his bearing went south last weekend. I actually have two boxes to do for my 90 (one recently bought on eBay that started life in a '78 R65), one will be a shelf spare. I just today bought an already overhauled box (have receipts) as a spare for my 65 Mono that has never been run, it started life in an '88 R100. I won't need to touch that one, though I may later ft it to the Mono and overhaul it's box.

Bill..................;-)
In Oz, sitting back with a beer after a job well done!!

[Chris_in_BC]

I don't remember what year bike this is, Chris.  Does yours have the felt?  What did it look like?  I would be afraid to think of what the inside of the input shaft looks like.  
.

Hi Rob,
It is 1981. BMW did away with the felt (like on my RS) and put in a very small oil seal. Lip and coil spring etc. But the push rod does run inside the input shaft, can't see any particular problem there. The amount of wear on the pushrod looks bad in the picture, but in reality it isn't a lot of metal missing. And it is a smooth ridge so has been worn over time, minute particles which should have migrated to the magnetic plug.
I agree with Airhead that it was probably me that was hamfisted at some point putting the pushrod in, but the outer seal and bearing etc was all clean and secure.


  

[Chris_in_BC]

Bill..................;-)
In Oz, sitting back with a beer after a job well done!!

Congratulations, Bill. Want to attempt that myself one day. Have another beer.. will that be Swan lager?
Chris

[Ed Miller]

Chris, why did you have the clutch push rod out?  I don't know what caused that, my '81 is smooth there.  Were you leaking oil out the back?  Some oil, I THINK, is supposed to lubricate your throw out bearing, so I never though that rod was supposed to be oil tight.  

If no tranny oil is leaking out, I would probably keep using that rod until time to change the clutch, when I (on my bike) intend to replace all the clutch parts and the throw out bearing, just like I do on cars, only for more money.

[Chris_in_BC]

Chris, why did you have the clutch push rod out?  I don't know what caused that, my '81 is smooth there.  Were you leaking oil out the back?  Some oil, I THINK, is supposed to lubricate your throw out bearing, so I never though that rod was supposed to be oil tight.  

If no tranny oil is leaking out, I would probably keep using that rod until time to change the clutch, when I (on my bike) intend to replace all the clutch parts and the throw out bearing, just like I do on cars, only for more money.

Ed,
 The oil seal is too stop oil leaking forward, otherwise oil thrown up onto the throwout bearing from the gearbox proper would migrate up the inside of the input shaft and come out in the clutch area. On the older bikes they had the felt seal do the same job.

I normally remove the clutch pushrod when I am cleaning the throwout bearing and assorted pieces. I do this whenever I have the gearbox off for lubing the input shaft splines. How or why or when I messed up the oil seal I don't know, but I said previously I found it last year when I had the rear cover off to fix a blown out cover gasket. What I didn't notice at the time was the wear on the clutch rod, although to be fair I had two days to reach Mexico and I was in a rush.

I will be looking for a used part as only the updated part is available now,  meaning new clutch rod and bearing package.
Chris

[airhead]

Congratulations, Bill. Want to attempt that myself one day. Have another beer.. will that be Swan lager?
Chris[/quote]


Good call Chris, but then, as right at this very moment, I'm being a traitor to my State and having a Hahn Light (Eastern States brew). It's been a scorcher today as with yesterday, in the high 30's Deg C.

The box job was made heaps easier by the fact the guy's box we were working on has a CNC milling machine, and I found the plans for the clearance plate in Joergs Motorcycle Pages, along with the .dxf code which, with some slight modifications, was fed into his machine so we had a plate to work with. He donated it to the club for future use, otherwise I was just going to use Plastigage to work out the shimming. It's great what can be achieved with the internet and a group of guys with a common purpose. That's what I felt pleased with as much as the actual job.

Bill.........................;-)