Clutch pushrod actuator oring replacement- how the hell could i bugger it up?

[earemike]

Swapped out the oring by the thrust bearing

Reassembled & now the clutch doesn’t disengage???

Adjusted the nut at the rear of the arm - set the clutch cable - no luck

If I wind the clutch cable far too tight I can get the clutch to disengage.

I thought this would be pretty hard to screw up - but I’ve done it!

I could pull it and reassemble - might get lucky - but how the heck did I screw up?

 Anyone else had this happen or can offer the wisdom of a greater mind?

Thanks, I’ll go back to lurking 

[Kiwi_Roy]

No need to lurk, welcome to the forum.
I see by your line-up you are no stranger to Guzzi
Tell us a little more about what happened and which one of your Guzzi it is and someone will be along shortly.
You have the world authority on all things Guzzi and mechanical on your doorstep.

[pete roper]

Did you also replace the clutch pushrod seals when you did the O-Ring?

[earemike]

Did you also replace the clutch pushrod seals when you did the O-Ring?

Hi Pete,

No, only popped the lug hou the back (with thrust bearing & washer) - bike is still assembled.

[earemike]

No need to lurk, welcome to the forum.
I see by your line-up you are no stranger to Guzzi
Tell us a little more about what happened and which one of your Guzzi it is and someone will be along shortly.
You have the world authority on all things Guzzi and mechanical on your doorstep.

Thanks Roy,

My lemans 5 speed - removed the actuating arm to slide out the small piston which holds the oring. As the thrust bearing and washer should slide back over the pushrod I’m scratching my head - obviously something isn’t aligned right 

[acguzzi]

sounds like disassembly is required regardless, I think you are saying you have to apply excessive force to get the clutch to engage, in which case I'd suspect the new O ring has gotten jammed up when the piston was re-inserted.

[Old Jock]

I'm wondering if the pushrod has dropped, or moved somehow and is no longer engaging the piece in the center of the clutch. It shouldn't but it's about all I can come up with, or the O ring getting shredded and gumming the whole thing up as has been mentioned

I take it that all you replaced was the rear O ring, did you pull out the whole pluger assembly including the thrust bearing or just the rear section leaving the front piece in place?

First I'd check the O ring is Ok and it's all mating together as it should, if that is all good then, sorry to say, but, I think the box will need to come out to investigate furhter.

John

[malik]

The thrust washer didn't collapse when you got near to it, did it? You can take that out with a magnet & check it when you check on how the new o-ring is doing.

[jacksonracingcomau]

The thrust washer didn't collapse when you got near to it, did it? You can take that out with a magnet & check it when you check on how the new o-ring is doing.

either that or the bearing face washer jumped ship
result same new thrust washer needed then readjust
as pete said, chuck new pushrod seals in while there