Clutch & Gearbox Mystery. Heeeellllp

KR1 Man · Post by **KR1 Man** » Wed Jun 10, 2009 4:56 pm

KR1 Man calling. Mine is experiencing a clutch and gearbox mystery which so far I have been unable to solve completley. This is what is happening: Put her into 1st or 2nd (from neutral) there is an element of creeping foreward, (other gears fine). Pull up at lights with clutch lever in, and the same happens. I have put this down to clutch drag. Have had clutch out twice and de-burred everything. Gearbox has been out and checked & is fine. Selector mechanism/drum/forks all the same. Clutch drum assy inspected by local Kwak dealer mechanic (with 'in the day KR experience') and all ok. New friction plates (EBC) Steels(Gen) Springs(Gen) Steel rings (Gen) Circlips (Gen) bolts and thrust bearing. I have 'turned around' the thrust washer and re-assembled using genuine gaskets, and still she creeps and won't disengage fully in 1st & 2nd. Also selection into these gears is 'notchy' Who has had the same and
cured it completely? Iam at a total loss as to what it is now. Thought possibly the push-rod itself. Heeeeeellllllp. Best regards, KR1 Man.

the-elf · Post by **the-elf** » Wed Jun 10, 2009 5:09 pm

I had the same problem and cured it but it was ages ago. IIRc the thrust washer was partly to blame but also the activating arm, in the clutch cover was worn as well (where it presses on the thrust washer) and wasn't operating the clutch fully.

You have adjusted the cable correctly as well?

JanBros · Post by **JanBros** » Wed Jun 10, 2009 11:11 pm

the-elf wrote:also the activating arm, in the clutch cover was worn as well (where it presses on the thrust washer) and wasn't operating the clutch fully.

KR1 Man · Post by **KR1 Man** » Thu Jun 11, 2009 3:44 pm

KR1 Man calling. Thank you for your help, bit unsure about 'activating arm pressing on the thrust washer', which piece(s) do I need to get? From what I see on mine, the clutch release lever (which the cable attatches to) fits into the mounting casing and comes into contact with the push rod which sits in the clutch release bearing. The bearing is a press fit into the holder which keeps the clutch springs in place.The holder is bolted to the clutch hub and the thrust washer is behind it. Please point me in the right direction [-o< Regarding the bits, the thrust washer is n.l.a. and to the best of my knowledge, so are the release lever and the push rod. [-o< [-o< [-o< Does anyone on the Forum have spares of these items?????? If so please let me know price + p.p. Ps. apologies for the descriptive text at the start, had to consult Big K's service manual for guidence. Best regards and thanks, KR1 Man.

dougindoors · Post by **dougindoors** » Thu Jun 11, 2009 4:42 pm

maybe a daft answer is the clutch cable streching, had this before on old cables the steel wires loose their temper and unwind internally allowing the cable to elongate. worth a look.

KR1 Man · Post by **KR1 Man** » Thu Jun 11, 2009 5:33 pm

Hi Doug, KR1 Man calling. Thanks for the idea but definitley not the cable, have both new & used. It looks like the actuating lever ought to be at an angle of something less than 'almost' 90 degrees, so now searching for good used lever/pushrod and thrust washer Any chance?????????? Best regards, KR1 Man.

the-elf · Post by **the-elf** » Thu Jun 11, 2009 6:18 pm

If you take the clutch cover off and look at the acivating arm on the inside you'll see a flat which presses against the push rod. the arm wears at the point were it pushes on the rod. and this causes the problem. its not a brillent desisn as I replaced mine a couple of years ago and its already starting to show signs of wear again.

KR1 Man · Post by **KR1 Man** » Mon Jun 15, 2009 7:10 pm

KR1 Man wrote:KR1 Man calling. Mine is experiencing a clutch and gearbox mystery which so far I have been unable to solve completley. This is what is happening: Put her into 1st or 2nd (from neutral) there is an element of creeping foreward, (other gears fine). Pull up at lights with clutch lever in, and the same happens. I have put this down to clutch drag. Have had clutch out twice and de-burred everything. Gearbox has been out and checked & is fine. Selector mechanism/drum/forks all the same. Clutch drum assy inspected by local Kwak dealer mechanic (with 'in the day KR experience') and all ok. New friction plates (EBC) Steels(Gen) Springs(Gen) Steel rings (Gen) Circlips (Gen) bolts and thrust bearing. I have 'turned around' the thrust washer and re-assembled using genuine gaskets, and still she creeps and won't disengage fully in 1st & 2nd. Also selection into these gears is 'notchy' Who has had the same and
cured it completely? Iam at a total loss as to what it is now. Thought possibly the push-rod itself. Heeeeeellllllp. Best regards, KR1 Man.

the-elf · Post by **the-elf** » Tue Jun 16, 2009 8:14 am

Hi, Are you sorted yet or do you still need one?

KR1 Man · Post by **KR1 Man** » Tue Jun 16, 2009 8:08 pm

KR1 Man calling The elf. Not yet still trying to source actuating arm, pushrod and thrust washer. Have sent you a pm with my contact details. Having loadsa fun/black fingers while she's off the road though, polishing all that ally + stainless. Have now got back as far as footrest hangers which got polished on the Inside this morning, along with their hex bolts; really looking foreward to doing swingarm as polisher scored an own goal by doing the underneath in error, so loadsa 'groundwork' on it's way. Best regards and thank you; KR1 Man.

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Clutch & Gearbox Mystery. Heeeellllp

Clutch & Gearbox Mystery. Heeeellllp

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