Fj 1100 clutch problem..

KENFJ110085 · July 22, 2014, 02:08:44 PM

Hi guys, not sure if i should write and ask about this coz your all going to get a good laugh now..lol.. but i take the chance anyway..

well as many before me, i did the big mistake, starting my fj without the clutchslave on its right place, so push rod flys out and ended on the floor together
with a ton of oil, i almost called shell coz i thought i had found a new oil well

.. .. all started with i should change chain and sprockets on sunday for a a little over a week ago.. was in a hurry and thought i did give the chain some oil before i did put all on place again. ( yes i did know, don't start engine with clutchslave off... hmmmm how could i forget it

) not sure if the ball are missing, so i try to put all on places again. but clutch lever goes all the way in, doesn't work as it was working before i did the mistake, the clutch don't disengage like it should do, so i get sure of the ball are missing,, crawling on the floor for hours, but no ball(s) to find.. so i order 2 new ones on eBay from germany coz it have short shipping time.. i get this 2 new balls today, put one of them in the hole where i think the first one did fly out.. so then my new problem are, now it looks like i have two balls in the end of the push rod?

? i tighten the bolts on clutchslave, and the clutch are disengaged all the time now. i have also tried to bleed the cluchslave, released the bolts so clutchslave are mounted with a gap of 3-4 mm and now clutch works as it should do.. so my question are, why is it like this, what have gone wrong inside the clutch or???

hope someone can help me with this problem

Kenneth....

FJ_Hooligan · July 22, 2014, 04:05:02 PM

Many have reported losing their clutch pushrod in this manner. As far as I can recall, NOT A SINGLE ONE reported that they lost the ball bearing.

We have attempted to squash this rumor, but it seems that some still like to warn about the missing ball bearing every time this comes up.

As you've already described, your problem is you now have 2 ball bearings on the end of the pushrod. You need to get one out.

Try fishing it out with a strong magnet. If you can't get it out of the pushrod hole, you'll have to disassemble the clutch and get to it from that side.

Good luck.

KENFJ110085 · July 22, 2014, 11:43:03 PM

Hi fj Hooligan

thank you for yours answer, i think your right about i have 2 ball bearings now and to get it out, would be a big clutch job on coming weekend.. but what i cant understand is why didn't the clutch work as it should do after the blowout of push rod and oil??? it was really looking like the ball bearing was missing. clutch lever went all the way in, barely did disengage the clutch, so it was hard to get it in gear?

? clutchmaster and slave was OK and never touched under the change of chain and sprockets..

Bozo · July 23, 2014, 07:19:32 AM

Quote from: FJ_Hooligan on July 22, 2014, 04:05:02 PM
Many have reported losing their clutch pushrod in this manner. As far as I can recall, NOT A SINGLE ONE reported that they lost the ball bearing.

We have attempted to squash this rumor, but it seems that some still like to warn about the missing ball bearing every time this comes up.

As you've already described, your problem is you now have 2 ball bearings on the end of the pushrod. You need to get one out.

Try fishing it out with a strong magnet. If you can't get it out of the pushrod hole, you'll have to disassemble the clutch and get to it from that side.

Good luck.

Made the same mistake some time back, I'm fairly certain the ball cannot go out the hole where the push goes, as hooligan stated there should be one ball bearing not two.

With my pushrod I nearly speared my old border collie which learn't not to lay near the bike while I'm working on it.

movenon · July 23, 2014, 09:11:36 AM

If you shoved another ball in the guide you might try to magnetize the end of the push rod and pull try to pull the ball out from the left side. Might have to remove the seal that go's around the push rod shaft. They usually come out easy and are cheap if you need to replace it.
George

FJ_Hooligan · July 23, 2014, 12:20:01 PM

Evidently the ball will fit through the pushrod hole since Ken was able to add another ball.

Here's what I think happens. The oil pressure acts only on the pushrod. Starting the engine will cause oil pressure to eject the pushrod, but that pressure is not behind the bearing so it stays in place.

It's been a loooooong time since I've had a clutch disassembled. What I don't know is whether or not the ball can be dislodged and drop into the crankcase. Again, my guess would be that it can't drop out since Ken successfully added a ball without it falling out anywhere.

As for how to get one of them back out. Give George's method a try. Put a strong magnet on the pushrod and try to extract the extra ball.

In the future, take notice of the grunge mark that the chain goop deposits on the pushrod. That should be a good indicator of whether the pushrod in going in too far or not far enough.

KENFJ110085 · July 23, 2014, 11:18:06 PM

Thanks to all of you guys.. very much right, its no problem to push the ball bearing through the hole of the oilseal.. think the ball and push rod are around same diameter so the ball goes stright in. have tried with one magnet on the end of the push rod, was not strong enough to get the ball out, will look for a stronger magnet, but if im not able to find one, i will make a magnet by wraping a simelar push rod with copper wire and give it some DC.. sure worth a try before disamble the clutch... Just hope for the clutch wil work fine after got the 2nd ball out.. coz it didnt work as it should after the push rod blow out... and this made me sure of i was missing a ball bearing in there....

simi_ed · July 23, 2014, 11:24:31 PM

Ken don't bother making a rod to magnetize, you already have one! Use the existing rod, wrap & zap, you got your magnet to extract the ball. YUou could then de-mag it with a hammer ...

Ed

KENFJ110085 · July 24, 2014, 11:46:32 PM

Hi Ed

you'r right, i could use my already exsiting rod and magnetize it.. made me also think of i have a small vacuumpump, all i need is to find a small rubberhose how will fitt in the hole and try to suck the ball out in this way, if i cant do it by magnet.. worth a try.. maybe i already this comeing evening wil try this..

KENFJ110085 · July 27, 2014, 03:35:48 AM

hi guys.. wow.. i got the ball out now, by using vaccum and a clear 8-9 mm, 1m hose, all how was needed, to cut it straight in one of the ends, had some oil on it when putting the hose trough the oilseal, sucked in the other end with a pressure against the ball and there it comes out and did stop in the oilseal, used a magnet to pull the ball trough oilseal.. got also out the original ball and put it back in again, so now its only one ball there, did bleed the clutch and now everything back to normal and works very much fine again.. ready for kookaloo........ thanks to all guys for good advices.....

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Fj 1100 clutch problem..