R 1150 GS clutch issues
 

I have a 2004 r 1150 gs that has barely 30,000 Kms on it. Riding to work one day it revved out and wouldnt go into gear. Long story short, had the gearbox rebuilt by an engineer and rebuilt the clutch with my brother. I'm pretty sure we put the clutch back together properly. Once it was all back together, a test ride was in order. There was one noticeable problem though. when in gear with the clutch in if revved it would go forward and when the clutch was let out it makes a rattling noise. Also you can smell it getting hot. any thoughts as to what might be wrong? put it back together same way it came out. maybe we messed something up. trying to avoid a trip to the shop

It sounds like your clutch is dragging. It might be a problem with the hydraulic system, have you tried to bleed it?

You describe a rattling sound and this might indicate worn splines (input shaft gearbox or clutch). This might also give you a dragging clutch. Did you lube the splines with Staburags (or similar) grease?

everything was followed according to the book. tried bleeding it out just the other day again with a bleeder screw and it had no effect. took it for a ride down the street and it shifts ok, but i suspect the problem isnt occuring all the time. it made the sound sometimes and sometimes not. but it would go forward with it in gear whilst bike was revved. its all new clutch and gearbox. you think it might have something to do with slave cylinder? havent noticed any leaking fluids on the cement

i should also mention that it developed pressure when bled and didnt feel "soft". i dont think its anything to do with air. cant fathom whats wrong with it

Did you lube the splines on the input shaft (gearbox)?

sure did

Does it sound as the splines are slipping?

not sure if that is making the sound. sound happens most of the time when clutch is used. can smell the clutch getting hot after very little use say 1 minute or so(thats without riding it either) . i cant figure what it is. might have to take the thing apart again and look at it

Based on your descriptions it looks like the frictionplate is more or less stuck on the input-shaft.
The only two things I can think of which can cause this is worn splines (input shaft and/or friction disc) or that the friction disk is the wrong way (long splines should be toward gearbox).

It cant be the shaft since it is brand new. I'm thinking it might be the friction plate. I'm going to pull it apart tomorrow and have a look. hopefully its that

I pulled the hydraulic clutch slave cylinder off today to remove the gearbox. There was fluid around the slave cylinder.
Does it get oil from the gearbox and I am looking at oil?

Am I looking at brake fluid leaking from the slave cylinder?

I can't tell because I re-filled the gearbox with fresh oil only the day before.