bronze flakes

bushmechanic · Oct 20, 2008

just asked my dealer where all the bronze flakes in my filters come from.

he wanted to know the same thing and has had his bike apart to check but got no answers.

my bikes done 153 hours but has shed bronze flakes since about 20hours.

in the parts listing the only bronze I can see is in the 3rd gear inner and the little end.

its never a real concern as a one off thing but the supply of bronze flakes is consistent enough to wonder whats going on.

anyone know what it is?

regards
Bushie

Coastie · Oct 21, 2008

There's some bronze bushes on the rocker arms.
Are they large flakes or more of a fine dust size.
I had the fine dust in my oil and it had me buggered but it just turned out to be fine copper particles from the anti-seize I used on the side cover gasket.

Coops

bushmechanic · Oct 21, 2008

average flake size about 0.8mm squarish and about 0.1 thick in the first strainer though some smaller ones end up in the paper filter.

they're always there change oil every4 hours and filter 8-12hrs

Taffy · Oct 21, 2008

i get the feeling it's the little end. has the engine been rebuilt lately or had a piston re-fitted? it is possible to make a right hash of refitment.

you get a fat chipped edge and then when you bang the pin through there is a fat flake of bronze. i trust you have needle rollers in the clutch hub?

regards

Taffy

nizzo · Oct 21, 2008

I have seen bronze flakes coming from the small bushing that is pressed in the end of the one transmission shaft (where the clutch slave bolts onto the engine). The flakes were showing-up in the suction screen.
Nizzo

bushmechanic · Oct 21, 2008

ahh righto more bronze bushings than I thought. must be one of them obviously.

engines never been apart taffy, pretty sure id be able to hear the little end, ears like a bat. clutch should have rollers like in the parts book.

will follow this thread up when/if I open up the engine and find summink.

thanks, nizzo's onto it I think.

regards
Bushie

spanner · Oct 22, 2008

Bushi, I had very fine partials that looked like brass in the oil. replaced the valve guides that were very lose (100hrs).
Oil looked good since.
Probably not your problem but have a look while you have got it apart.
Best to inspect with the springs and seal removed. Have a look from the spring side mine had about 0.5mm gap at the top!

Cheers spanner

bushmechanic · Dec 11, 2008

orrite

the bronze flakes come from the small bushing as nizzo described. can check this by removing the clutch slave, don't have to open the box.

some larger bits of metal appear to come from a gear in 3 peices

my fault. i figure its done about .............. 60 000 shifts so its not too bad.

regards
Bushie

bushmechanic · Jul 17, 2009

just done another bushing in 20 hrs,

the end of the clutch push rod is not square so the clucth slave piston spigot thing gets rammed over to one side and floggs out the bushing.

squared up the rod end, should fix the issue. (i hope)

mantrap · Jan 3, 2010

I have started see in bronze flakes on the screen and filter now at 30hrs. I removed the clutch slave and it looks like this is were they are coming from. How do I remove the bushing and do I need to replace the plunger thing.

bushmechanic · Jan 3, 2010

check the end of the long rod to see if its square, replacing it is likely a gamble,

if its not square, square it up with a file. I ground a concave dish in mine and made some solid bronze bushes instead of the steel/sintered crap the stock ones are made from. I still get some wear from it but its finer bronze bits less likely to stuff up the gearbox bearing

the bushing came out with a hook tool, you could mangle it with a pick then pull it out or remove the outer clutch cover etc and knock it through with a drift.

bushmechanic · Jul 23, 2014

this is the late model sintered "bronze" bushing that often fails

these are in the early model gearboxes I have

home made brass bushing

haven't had a problem after squaring off the end of the pushrod

spanner · Jul 24, 2014

As Bushie says the ends of the clutch activating rod need to be square.

I think the original bush was something like 10mm long and the spigot on the slave piston is the same so the rod is unsupported in the bush when the clutch is fully engaged. The rod running in and out of the end of the bush wears the bronze away.
There is room to install a longer bush 15mm IIRC. Pushing an original bush in further, up to the shoulder might work also.

I turned one out of some manganese bronze which is pretty tough stuff.

bushmechanic · Jul 25, 2014

thats a good point spanner, i pushed the beggars right in

pic of unsquare end

bronze flakes

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