Not so good..

Message

fatboy · #1 Post by **fatboy** » Wed Jul 04, 2018 6:19 pm

Last two turns before arriving at work this morning, grabbed the clutch lever and it was solid like a brake lever at the end of its travel.
Popped the outer clutch cover off, a nugget of aluminium shaped like loads of crescents fused together fell out and the diaphram was covered in mega fine ali swarf.
Did not get chance to investigate further but it would seem that the pushrod may have fused itself to something.... or worse !
More tomorrow when I get the the bugger apart

#2 Post by **mangocrazy** » Wed Jul 04, 2018 8:00 pm

Best of luck, Paul. But large amounts of free ali doesn't bode very well...

D-Rider · #3 Post by **D-Rider** » Thu Jul 05, 2018 7:34 am

What can I say but "Oh Dear!"

Replacing the parts is one thing but convincing yourself that you've got all the little bits of metal from in there is another.

Hope it all sorts out OK.

fatboy · #4 Post by **fatboy** » Fri Jul 06, 2018 3:18 pm

Well it was due to a major failure of the slave cylinder, the piston seems to have gone beyond the extent of its travel and popped out of its bore which put the pushrod in contact with the inner diaphram washer.
Just to make it more interesting one of the pressure plate bolts decided to loosen itself and because of the extended travel of the pressure plate the bolt head was gouging into the diaphram washer, hence the sreies of crescent shaped fused together bits.
I will speak to the man at AP when he is back in on monday, the motor may or may not be dusted......
No nasty noises, no lock up so Im keeping fingers crossed

fatboy · #5 Post by **fatboy** » Mon Jul 09, 2018 3:29 pm

Not the disaster i feared !
Griff did not seem too worried by the swarf issue, most of it will be contained in the clutch housing, the oil filter and strainer will take care of the rest, the motor is really robust and will take a fair old beating he said.
And I now have permision to carry out the repairs in our HGV workshop, so don't have to worry about getting the bike home

Falcopops · #6 Post by **Falcopops** » Mon Jul 09, 2018 8:31 pm

that's a lot of good news, phew

D-Rider · #7 Post by **D-Rider** » Tue Jul 10, 2018 7:30 am

fatboy wrote:Not the disaster i feared !
Griff did not seem too worried by the swarf issue, most of it will be contained in the clutch housing, the oil filter and strainer will take care of the rest, the motor is really robust and will take a fair old beating he said.
And I now have permision to carry out the repairs in our HGV workshop, so don't have to worry about getting the bike home

Well that's a relief !

.... going in the HGV workshop ..... we await pictures of the first 8-wheeler Falco .......

#8 Post by **mangocrazy** » Tue Jul 10, 2018 5:36 pm

Good news, Paul - it's always a real uplift when something dire you feared doesn't come to pass. And being able to fix it at work is even more of a bonus...

fatboy · #9 Post by **fatboy** » Tue Jul 10, 2018 6:01 pm

Falcopops wrote:that's a lot of good news, phew

yep, too right that man !
Should get it done by the end of the week, thanks all for the pat on the back, however it will be leaving the workshop with a few less than 8 wheels

fatboy · #10 Post by **fatboy** » Mon Jul 16, 2018 2:13 pm

The fun starts (and stops ) here.
Begun the strip down,slave cylinder not at fault, master cylinder ok, release bearing and pressure plate ok, pushrod has many abrasions, probably from the swarf from the diaphragm washer.
Bit hard to work out WTF happened.
Clutch centre has decided it is NOT going to slide off its splines, even with the use of a puller, next will threaten the fucker with heat, if that does not work then I'm at a dead end.
Any useful suggestions appreciated

#11 Post by **mangocrazy** » Mon Jul 16, 2018 2:24 pm

Heat is probably your only friend here... If (as I assume) the clutch centre is ali and the spline is steel, then ali should expand faster than steel and should hopefully break whatever bond is holding the two together. A combination of plenty of heat, the puller and perhaps a dash of something like Wurth Rost-Off Ice (penetrating and freezing spray in one) might help.

fatboy · #12 Post by **fatboy** » Tue Jul 17, 2018 2:28 pm

Yes Graham, you are right, I will need heat and lots of it.....
That pesky old locking compound has been used to secure the clutch centre nut and must have worked its way onto the splines.
This will be a similar battle to doing the starter clutch.
Why is it never as easy as it should be ?

#13 Post by **mangocrazy** » Tue Jul 17, 2018 6:33 pm

Bugger, just hope it isn't the green thread lock. That really does take some shifting. Don't know why but an old album title by a band called Budgie came into my head there - 'In the grip of a tyre-fitter's hand'...

Break out the gas axe!

fatboy · #14 Post by **fatboy** » Sun Jul 29, 2018 4:03 pm

Well this is fighting me every step of the way, brutal heat and a workshop grade puller defeated the dreaded green locking compound.....
Only to find the clutch basket will not budge, shit. Further stripping down,clutch cover off and more applied violence. More time and resources at a time when both are stretched...
Getting my ass chewed at work for pointing out that you as managers can't actually manage and we as Union members are no longer prepared to work like fuck to cover your failings
And trying to pull of a finance deal on an RC8