R25/2 Clutch Pushrod Square Tip in Square Hole?

[Kurt in S.A.]

I asked this on another forum...thought I'd get your ideas, as well.  I've got the transmission in the bike, bolted in place finger tight.  But the clutch pushrod, the one with the square tipped end, is not mating into the square hole in the pressure plate.  I've used the kick lever to move the engine around and tried to coax the back end of the rod around to see if it will drop into place but no luck.  Since it doesn't drop in place, I can't install the clutch arm at the back of the transmission.  Any suggestions on getting the rod into place? 

Thanks...Kurt

[Kurt in S.A.]

[† Will]

I asked this on another forum...thought I'd get your ideas, as well.  I've got the transmission in the bike, bolted in place finger tight.  But the clutch pushrod, the one with the square tipped end, is not mating into the square hole in the pressure plate.  I've used the kick lever to move the engine around and tried to coax the back end of the rod around to see if it will drop into place but no luck.  Since it doesn't drop in place, I can't install the clutch arm at the back of the transmission.  Any suggestions on getting the rod into place?  Thanks...Kurt

Hi Kurt,
I made a simple tool to fit mine but it only works with a single piece rod.
If yours is a 3 piece original you can turn the rod from the gap between the the gearbox and the crankcase if you pull the gearbox back as far as it will go, then use use thin long nosed pliers or medical clamps.
Cheers.
Will

[† Will]

Hi Kurt,
I made a simple tool to fit mine but it only works with a single piece rod.
If yours is a 3 piece original you can turn the rod from the gap between the the gearbox and the crankcase if you pull the gearbox back as far as it will go, then use use thin long nosed pliers or medical clamps.
Cheers.
Will

PS - I tried many times to attach the photos and sketch of the parts, but no success. If you send me an email address I'll send them direct to you.

[Kurt in S.A.]

Will -

I am replacing the original 3-piece with the 1-piece rod.  I will send a message to you off-line.

Kurt

[4Taktix]

Maybe you got a burr / edge inside the shaft, if your tranny ran with the 3-piece-pushrod before,
so that your sqare-end does not go in far enough to even touch the spring-plate.
It is also possible, that there are differnces in the lenght of the replacement-pushrods for the different
R-models. Did you already compare the old 3-piece rod with the 1-piece rod ?
Sascha

[berndr253]

Hi Kurt,

if you have some difficulties to fumble the things together - put a thin tube on the end of the pushrod so that you can turn and push the rod from the outside of the gearbox. If the things are fitted use pressurized air to devide the tube from the pushrod.

Bernd

[† Will]

The answer is here -

[Kurt in S.A.]

The one-piece and three-piece rods were the same length overall.  I installed the new rod in from the front and it all slide through easily.  The rod will actuate the clutch, but the most aft thrust piece won't slip completely into the tranny housing because the rod hasn't seated into the square hole.

I've gathered all the parts that Will has suggested and will be making the little mandrel up today and hopefully getting a chance to try it out soon.  I'll report back.  I'm hoping this will do the trick...I don't want to move everything back a few inches in order to use a long pair of pliers to guide the rod to the hole in the pressure plate...way too much work!

Kurt

[4Taktix]

Brilliant little tool and idea - I think this is worth to be put under "Tipps & Tricks".
Karl ? Kahaaaarl ......
Cheers, Sascha

[† Will]

Brilliant little tool and idea - I think this is worth to be put under "Tipps & Tricks".
Karl ? Kahaaaarl ......
Cheers, Sascha

Many thanks for your kind comments Sacha.

[Kurt in S.A.]

Update...worked like a charm!  Took longer to make it than use it!  I had to shorten everything to about 50mm in order to fit into the transmission hole and still clear the backbone behind the engine.  I didn't use a tapped hole on the back end...I just used a small through-bolt with a nut and washer to clamp the assembly together.

Excellent suggestion...really saved my bacon on this one.  Thanks, Will!

Kurt