Hi guys,
I am in the middle of my teardown inspection and would love to post pictures but even with signing up with servimg.com I am still unable.....HELP  
 
I pulled the transmission to check and lube the splines (Honda moly, Stabaurags doesn't seem to be available here) everything looked great. I was told the bike had sat for 2 years and no maintenance in the 2 years prior but every thing was almost like new! 
Upon re-assembly I wanted to check the clutch throw and as I am still waiting for my replacement clutch cable I just manually pushed the transmission clutch lever in. 
I was expecting the rod to push in and then the clutch fingers to push back. First attempt was as expected but when I pushed harder the second time the rod pushed through and stuck.
I released the lever, undid the boot and manually pulled back on the rod. It came out with a POP! Naturally I tried this 2 or 3 times more (like you do   ) with the same result.
It would seem that the clutch fingers (or spring plate) was pushing beyond it's center point or perhaps the rod was jamming. I can't assertain exactly what is happening.
Has any one experienced this before?
If it's doable is it OK?
Any help would be so welcome.
Cheers,
Rob

Check here>https://www.youtube.com/watch?v=FhC0ou_ubQ4&feature=player_embedded rossko's help video.

If the adjustment bolt on the actuation arm is set too far in that could happen. Make sure of the correct adjustment as per the manual at 73- 76mm

Thanks Rick. I got the measurement but what I was saying is that when I push the actuating arm in with my hand (no cable attached) I can push the rod far enough in that it seems the diaphram spring plate over flexes beyond the return point.
Is this supposed to even be possible ?
Rob
p.s still working on the picture thingy

If the adjustment bolt is too far in it will probably do that

To get the adjustment correct you will need to have the cable in position.
Not saying that this is the problem but it's the only thing I can come up with
I do have one more thing make sure the throwout bearing piston is in the right way round with the pushrod going into the ball race centre

k-wopper-w900 wrote:Thanks Rick. I got the measurement but what I was saying is that when I push the actuating arm in with my hand (no cable attached) I can push the rod far enough in that it seems the diaphragm spring plate over flexes beyond the return point.
Is this supposed to even be possible ?
Rob
p.s still working on the picture thingy

I believe it is possible to overflex the clutch spring plate.  I did so while working on my K75 clutch this weekend.  When I reinstalled the transmission, I took a small amount of Honda Moly 60 and smeared it on the end of the pushrod, enough to give it a light coating.  It might help your sticking problem, but in actual operation, the withdrawal arm will not push the rod in so far as what you can do by hand.

Pushing on the actuating arm will push the rod a lot further than pulling the clutch lever.
Posting Pictures https://www.k100-forum.com/t998-posting-pictures-and-movies

That's the information I was needing. The fact that the push rod can extend that far in meaning that I was missing something.
I feel much better about it now. 
Thank-you ever so much. This forum is awesome.
Rob