1200 8V Clutch Pushrod Length

[John Warner]

I've known for a while now, that when replacing a Clutch on an 8V 1200 (and possibly others?), there is a Tool required to determine what length of Pushrod to fit (of the Four Lengths available).

I recently acquired said Tooling (many thanks again Mr Roper!), but continued research and queries on various Groups and Forums suggests that he Tool is pretty-much redundant.
I can't find anyone that has used one, or knows why it's (supposedly) needed.
All the owners/techs who have responded say they've never used it, and have never had any issues after replacing a Clutch.

So the questions are;
1. Why is the Tool needed?
2. Why are there four lengths of Clutch Pushrod?
3. Has anyone replaced a Clutch on an 8V 1200, with or without using the Tool, and if 'without', were there any issues afterwards?

Even Mr Roper himself is not sure why the Tool exists, and has replaced many Clutches on various models without having to use the Tool, with zero problems.





Thanks.



.

[guzzisteve]

I used one cause it was there, 3 times. I don't think they trusted the center plate on clutch or maybe the puck on the other end. Regardless, I have never needed a different pushrod after replacing the clutch. I guess in case you can't figure it out, they'll make it easy.  Just in case you need one. I would think they didn't sell any. Haven't tried to see if they have any. If I EVER need that tool I know where there is one. I hope I never change another one, Last one was a year ago. Don't miss that at all sorry, I'm retired now. My stuff runs fine.

Just looked up all the part #'s John,  NONE Exist in the US new and part numbers are not listed anymore. 6 different rod lengths.
Sure glad I ride old bikes, you can get most anything

[John Warner]

Thanks Steve.
That's another vote then for WTF?        

I'll probably strip down my 'project' 2008 Stelvio over Winter (it's basically a Frame with Engine/Gearbox fitted at the moment, with the rest in boxes).
Gearchange isn't returning, so I have to take the Box off anyway, will have a play with the Tooling then.

[guzzisteve]

I can not believe those pushrods are not available any more. So if you loose the clutch & the center plate takes out the end of pushrod you are screwed.
Just buy a new bike, why would anyone want to ride anything else.

[John Warner]

Maybe someone at the Factory realised no-one had ever bought one, so they discontinued them?

Also, it's just a 6mm Diameter Steel Rod, would be easy to make one from Stainless or Silver Steel.
Cut with a slitting Disc in an Angle-Grinder, polish the ends with increasing grades of Wet-n-Dry Paper, then heat the ends to Cherry-Red and quench in Oil, simples.

[guzzisteve]

That tool you have should tell you which one you have 183mm -----  185.5mm You may be able to get them. Haven't looked at TLM yet.

Just looked , NOPE no #'s listed, gone for good.