hi again, after finally getting the k100rs to start after replacing the temperature switch i was shocked to find  that prior to my first test ride i lost my shifting , as in when i let off the clutch it jumped into first gear,(same with second) and i had to use the kill switch on that first ride as engaging the clutch wasn't enough to reduce all the power to the real wheel,    i replaced the clutch and  clutch cable , when i serviced the splines and replaced the rear main seal. i put on a few hundred miles after that work and then the bike basically sat for the last year, 

with the engine off it will roll  in neutral and it will go back into neutral. 

anyhow so far i have adjusted the clutch cable and inspected the bearings and spring under the clutch boot arm and didn't see anything out of the ordinary, i adjusted the detached clutch cable (venhill) to 75mm and reattached the cable to the arm, this allowed me to slightly raise the arm up with my hand , like when pulling on the clutch lever, but after screwing in the adjustment screw thru the boot arm until it stops and then tightening the lock nut i noticed then that i could not push up on the arm, with two hands, and the clutch lever is tight, 

should the arm be able to be pushed up after being adjusted? any ideas in general? 

discouraged

I leave the cable in position to adjust for 75mm, once done lock the adjuster.
 Now adjust the screw through the rubber boot on the clutch arm to achieve a 4mm free play gap at handle bar lever.

thanks for the response ungaas. the cable adjustment doesnt seem to be helping my problem so I'm not sure  where to go from here? a worn out spring under the clutch boot (60k)? no idea but this is starting to scare me.  

 from the boot arm going in it looks like the pushrod is behind the bearing and if that   had broken what would the symptoms be? 

replacing the friction plate was pretty straightforward but i'm thinking this might best be left to a bmw mechanic in case i take it apart and can't figure it out what is wrong and have to put it back together again and then take it to the mechanic anyway.    

i was hoping with all the work I've done to the bike there might be a time when i wouldn't have to worry about something messing up, is there any truth to that? or are all of you so experienced mechanically that you never really worry something might go awry when in use?

Flip, while putting it all back together last time did you follow specified torque amounts to the fasteners? Something(s) could have backed out and you've no longer a clutch unit that's operating as designed. Just a thought, but this very weekend I replaced the friction plate on my bike and had to go back in after nearly having it all buttoned up just because I couldn't remember if I torqued properly the nut for the clutch housing/output shaft. Kinda that 'did I turn off the water back home?' kind of feeling. 

Keep me posted; eager to see what's ailing her

The clutch actuation arm will be strong but it should be possible to engage it with the strength of one arm. If you are pushing with two hands and not moving it, something is wrong.

When you had the transmission out for the service, did you notice whether the clutch throwout bearing was a single piece plastic shrouded unit or a three piece unit? You might have reinstalled the clutch push rod incorrectly. The symptoms sound like you might have a bent pushrod. Was the reassembly of the transmission easy and event free or sis you have a struggle?

Flip2 wrote: i was hoping with all the work I've done to the bike there might be a time when i wouldn't have to worry about something messing up, is there any truth to that? or are all of you so experienced mechanically that you never really worry something might go awry when in use?

Flip, not a soul here cannot relate to that feeling. Just learn to not worry about it.  Measure twice, cut once. 

Do know that the further you get into your bike the deeper your knowledge gets. You'll be able to identify the source and cause of nearly every sound, smell and feeling coming from it and what to do about it, if anything. Fat lot of good that does after burning up the whole day/night converting your knuckles into hamburger and your garage into grease pit 

okay, thanks for the advice . evidently i should have rode the bike a bit longer and the "stuck clutch" would have become unstuck as that is what happened when i took it to the mechanic and he rode it around the block,live and learn, i hope. 

the theory is the bike sat for nearly a year, inside, but i sprayed it off before it sat for that time, and some corrosion on the clutch caused it to stick.  there is a chance it was outside at some point as someone else took it from me to work on it so it could have got wet then maybe. anyhow it s been fine since . cheers!