Hey Vox, why is it that I can put ever so light pressure on my clutch lever and the box O rocks stops? I even thought of a small shim or spacer at the clutch master cylinder to hold the lever in a little, but figured someone else would have thought of that years ago, so discounted it as a bad idea
Yes I find the same thing.
There are two issues to the noise. I think there is is a tendency for the clutch rod to rattle in the long shaft hole. On most cars, there is a tension spring holding the clutch fork bearing against the push rod and the bearing is running free most of the time. On the K if they did that then the teeny bearing in the slave would wear out faster than the seals! So when the clutch is released, the rod is left rolling inside the shaft. When I put mine back I found the pushrod was something like 9mm in a 10mm hole. Just for kicks I wrapped some ptfe tape around 2 ends of the pushrod and when it all went back, a lot of rattle had gone. But then as I might have expected, it came back after 1500 miles. I should have machined up a couple of short ptfe tubular inserts, but 0.5mm of wall thickness would need some skill. Now, BMW started supplying that little foam thingy that slides on the push rod. I do not think it is to stop clutch fluid running down, so much as stopping some rattle. It won't do that for long though.
The second contribution to the rattle are the internal shims on the output shaft that Bob (RFW) has explained very well.
When you hold in the clutch and despite the slave bearing, there will be some end force, friction and drag put on the output shaft and I think that also pre-loads the crank/output shaft gears stopping them from oscillating.
Unfortunately, when I had those internal parts in pieces I did not give the shims enough attention as I had not read Bobs post. - I now wish I had.
I am waiting until I get another clutch problem with an excuse to go inside, but I did such a good job nothing has gone wrong yet and I shall live with the 'rocks'. Anyway, you should not be spending time sat at stop signals with these bikes.!
Apart from fine tuning the shims, I remember what the light weight ali clutch housing looked like and I wonder what would happen if it was a bit heavier, like a small flywheel?
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