Hi all and thanks for letting me join in the forum. I am in the middle of replacing the clutch plate on a 1997 K1200RS and have came across an issue. Itís not my bike so I canít tell how the bike was before I started work on it. My problem is that when everything is rebuilt and the slave bled properly I can only pull the clutch lever half way before I get a solid lever. Itís not disengaging the clutch correctly and will still move the rear wheel when the lever is pulled. I have had the box off and on numerous times and it is built correctly as far as I can tell. New o-ring and nut used for reassembly. Has anyone ever came across this before or has anyone any ideas as to why this may be happening. I did ride the bike into the workshop before dismantling and the clutch lever went in the full way no problem. Thanks in advance
YES we have seen this before - BOTH on the old (now closed) K1200RS forum on "www.I-BMW.com" AND ALSO on the K1200LT forum on www,BmwLt.com.
THE SHORT AWSWER IS THIS: You will have to open the clutch again and take measurements of new friction plate you bough AND the pressure plate you are using (old or new).
THE LONG ANSWER IS there are 2 "potential" problems / reasons that may cause this:
1) On EBAY and a few other site, they sell cheap "after-market" clutch friction plate that is more than 6.1 mm thick. This is not allowed based on the BMW specs where a new OEM friction plate (made by SACHS) is normally 6 mm. Most after-market disc are OK and are within specs, but not the cheap "made in China" friction disc without any brand or stamps on the disc - I have seen some as thick as 6.5 mm.
Because of the design of the clutch pack and the curvature of the Diaphragm spring, any friction plate more than 6.1 will cause the push-rod to be shorter at exit of the transmission (into slave). Although this sounds counter to common logic, you have to understand the design of the clutch pack - in fact BMW does warn you indirectly by saying in the owners manual that the fluid level in the clutch master (at handlebar) will go up as the clutch wear (meaning the push rod goes out more into the slave when the friction plate is thinner).
2) the 2nd issue is specific to early models of the K1200RS (1997 in Europe/Canada and some 1998 in USA): On the early models, BMW has used a thicker Pressure-Plate (see attache photo for measurements AND part numbers). All other models (mid 1998 to end of production) have the newer / thinner Pressure-Plate with a different part number.
The old thicker Pressure-Plate AND the old thinner friction-Plate (was matching pair) are BOTH obsolete and are no NO LONGER available in parts fiche. So if your 1997 models has the older / thicker Pressure-Plate (check my photo measurements), you need to buy a new Pressure-Plate that should match the new specs. If you choose to buy a used Pressure-Plate you do not know what you are getting: both in terms of thickness AND in terms of surface damage...
I do not know where you are based, but MotorWorks in UK has very good prices for these clutch parts. They sell mainly the SACHS parts that are in fact exact equivalent to OEM (factory was using SACHS). Even with shipping cost, I can get them shipped to my place in Canada for much less than most suppliers / dealers in USA.