Clutch

[RPGR90s]

I'm helping a buddy with a R60/5 where the clutch works but the engagement point doesn't happen until the lever is nearly all the way out.

I've checked cable and lever adjustments and they're perfect.

I had to remove the rear end to address some leaking seals so decided to tear into a visual inspection of the clutch.

Clutch Spring height is .6940", which appears within spec.
Friction disc thickness is .2345" which is within spec.

However, this clutch has six .154" (4mm) thickness spacers installed between the pressure ring and pressure plate. (BMW p/n 21 21 0 070 511).

I'm curious why they're used (I've never seen them on R90s's, R90/6's or R75/5's I've worked on)?

And.....would their use would be causing the late engagement of the clutch?

Thanks much,

RPGR90s

 

[20774]

Those washer/spacers were used on the /2 era clutches as well. They had various methods of spacing the parts and to allow the dust, etc, to escape. I don't think that's the issue.

Any chance that the clutch pushrod is the wrong one? Anton has some pictures of various pushrods:

http://largiader.com/articles/throwout/

From his pictures, the early /5 should be 215.5mm long.

Proper clutch cable? You probably have clutch actuation adjustment down pat, but here's what's been posted as recommended by Tom Cutter:

https://forums.bmwmoa.org/showthread.php?39773-No-adjustment-left-in-Clutch-rod&p=499945#post499945

 

[RPGR90s]

I believe the Pressure plate thrust rod contact area is worn. The Thrust rod measures the correct length and is straight.