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DT125R FORUM

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  4. Weird clutch problem

Weird clutch problem

Scheduled Pinned Locked Moved Engine
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  • Biker_123B Biker_123

    @Raydt If I put the piece of rod I took out back in and move the clutch perch there's definitely some movement I can feel the remaining broken piece move against it! I've pretty much tried everything to get the stuck piece out along with the bairing which looks mushroom shaped but it's not for moving. I've tried magnets, tapping it with a soft faced mallet and using magnets at the same time,oil etc no idea what else I can do really other than half the thing in 2 which is just annoying as the engine was running spot on until this happened... Just wish there was another way to get this rod out

    CalumC Offline
    CalumC Offline
    Calum
    wrote on last edited by Calum
    #22

    @Biker_123 Am I missing something here. Why do you need to get the rod out . Just place in another bearing to space it out some more and put it all back together and adjust it properly.

    I literally must be missing sometbing.

    Always Originate, Never Pirate!

    Biker_123B 1 Reply Last reply
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    • CalumC Calum

      @Biker_123 Am I missing something here. Why do you need to get the rod out . Just place in another bearing to space it out some more and put it all back together and adjust it properly.

      I literally must be missing sometbing.

      Biker_123B Offline
      Biker_123B Offline
      Biker_123
      wrote on last edited by
      #23

      @Calum I would do that if it where possible. The problem is the last person who worked on the engine has made a mess of the clutch instead of it consisting of a clutch push rod followed by a bearing they have used x2 smaller rods and multiple small bearings that are now stuck inside the rod shaft! The reason for me needing to get the last piece of the rod and bearings out is that it's collapsed in on itself so was no longer able to reach the pressure plate so couldn't be adjusted either way, I believe the last piece of rod in the shaft is bent or the bearings that are left in there are preventing it from coming out.I'am not very good at explaining these things lol hopefully you understand 🙂

      Every problem has a solution

      R 1 Reply Last reply
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      • CalumC Offline
        CalumC Offline
        Calum
        wrote on last edited by
        #24

        Sounds like you will have to split the cases then in that case. In which instance you may as well rebuild thr engine.

        Always Originate, Never Pirate!

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        • Biker_123B Biker_123

          @Calum I would do that if it where possible. The problem is the last person who worked on the engine has made a mess of the clutch instead of it consisting of a clutch push rod followed by a bearing they have used x2 smaller rods and multiple small bearings that are now stuck inside the rod shaft! The reason for me needing to get the last piece of the rod and bearings out is that it's collapsed in on itself so was no longer able to reach the pressure plate so couldn't be adjusted either way, I believe the last piece of rod in the shaft is bent or the bearings that are left in there are preventing it from coming out.I'am not very good at explaining these things lol hopefully you understand 🙂

          R Offline
          R Offline
          Raydt
          wrote on last edited by
          #25

          @Biker_123
          How does the clutch arm come out, if you can get the clutch arm out without stripping the box then possibly you could push a piece of wire down the clutch shaft hole and maybe push out the broken bits, I wouldn't use oil in the shaft, I would use a solvent to try and wash out any small bits.
          If you still cannot get the broken bits out then it's rebuild time.

          Biker_123B CalumC 2 Replies Last reply
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          • R Raydt

            @Biker_123
            How does the clutch arm come out, if you can get the clutch arm out without stripping the box then possibly you could push a piece of wire down the clutch shaft hole and maybe push out the broken bits, I wouldn't use oil in the shaft, I would use a solvent to try and wash out any small bits.
            If you still cannot get the broken bits out then it's rebuild time.

            Biker_123B Offline
            Biker_123B Offline
            Biker_123
            wrote on last edited by
            #26

            @Raydt It literally just lifts out when you unclip the spring at the top but I've had success and managed to remove the broken piece and bearings without splitting the cases so it's all repaired now and I put in a new push rod and bearing and brand new clutch plate kit.

            Every problem has a solution

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            • MightymanM Offline
              MightymanM Offline
              Mightyman
              wrote on last edited by
              #27

              Good to hear!

              TDR 125 - 2001

              1 Reply Last reply
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              • R Raydt

                @Biker_123
                How does the clutch arm come out, if you can get the clutch arm out without stripping the box then possibly you could push a piece of wire down the clutch shaft hole and maybe push out the broken bits, I wouldn't use oil in the shaft, I would use a solvent to try and wash out any small bits.
                If you still cannot get the broken bits out then it's rebuild time.

                CalumC Offline
                CalumC Offline
                Calum
                wrote on last edited by
                #28

                @Raydt said in Weird clutch problem:

                @Biker_123
                How does the clutch arm come out, if you can get the clutch arm out without stripping the box then possibly you could push a piece of wire down the clutch shaft hole and maybe push out the broken bits, I wouldn't use oil in the shaft, I would use a solvent to try and wash out any small bits.
                If you still cannot get the broken bits out then it's rebuild time.

                Would not want to be using a solvent mate. All of the seals will dry out and that will be game over then. You need to use oil to keep the essential components lubricated

                Always Originate, Never Pirate!

                Biker_123B 1 Reply Last reply
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                • CalumC Calum

                  @Raydt said in Weird clutch problem:

                  @Biker_123
                  How does the clutch arm come out, if you can get the clutch arm out without stripping the box then possibly you could push a piece of wire down the clutch shaft hole and maybe push out the broken bits, I wouldn't use oil in the shaft, I would use a solvent to try and wash out any small bits.
                  If you still cannot get the broken bits out then it's rebuild time.

                  Would not want to be using a solvent mate. All of the seals will dry out and that will be game over then. You need to use oil to keep the essential components lubricated

                  Biker_123B Offline
                  Biker_123B Offline
                  Biker_123
                  wrote on last edited by
                  #29

                  @Calum I just used a spot of transmission oil down the shaft when I tried it that way hopefully that's ok and won't have caused any damage , seems to be running a treat now anyway so I've been lucky but if the worst came to the worst I would just split the case and renew everything.

                  Every problem has a solution

                  CalumC 1 Reply Last reply
                  1
                  • Biker_123B Biker_123

                    @Calum I just used a spot of transmission oil down the shaft when I tried it that way hopefully that's ok and won't have caused any damage , seems to be running a treat now anyway so I've been lucky but if the worst came to the worst I would just split the case and renew everything.

                    CalumC Offline
                    CalumC Offline
                    Calum
                    wrote on last edited by
                    #30

                    @Biker_123 Yeah mate sounds the trick. Well done for fixing it.

                    Always Originate, Never Pirate!

                    Biker_123B 1 Reply Last reply
                    1
                    • CalumC Calum

                      @Biker_123 Yeah mate sounds the trick. Well done for fixing it.

                      Biker_123B Offline
                      Biker_123B Offline
                      Biker_123
                      wrote on last edited by
                      #31

                      @Calum Thanks

                      Every problem has a solution

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