fla-shadow wrote on 12/31/69 at 16:00:10:I have the clutch working now. My third attempt at re-assembly worked.
I think that the Clymer manual has an error in it. It calls for disc # 1 to have the smallest thickness at 3.00 mm and disc 2 to be larger at 3.5mm. My EBC kit had 5 discs at 3.0 mm and 1 disc at 3.5 mm. When I installed the 3.0 mm disc in the #1 position, it was hitting on the wave washer and preventing the clutch assembly from fully closing. This must have resulted in the pushrod from being further away from the actuator arm and not giving any pressure on the clutch lever.
I measured the old clutch discs that I had already removed and found out that the one unique disc was the thickest, (near 3.5mm), and the other 5 were smaller, (near 3.0mm). Then I cross referenced the EBC part Number to verify that I had the right kit.
Next, I checked out the microfiche on 3 websites to eventually discover that the inside diameter of disc # 1 is supposed to be 120mm and the rest of the discs should be 116 mm. The thickest disc in my kit measured 120 mm, so I tried installing it in position #1. The 120 mm diameter fit past the wave washer and the clutch assembled properly. I only push tested the bike so far. I will finish putting on the exhaust tonight and take it for a test drive tomorrow.
Thanks for reminding me to read the directions. When I took my time on the final assembly, I spent more time on the pictures than on the wording. It took some time to find the error in the book, but the clutch appears to be working properly now.
Thanks,
Fla-shadow
I don't even know why the Clymer goes into the thickness of Disk 1 or 2....
Disk 1 is the only one that has a larger ID then all the rest. That is so that it fits over the wave washer.
But since you had them switched around, it makes perfect sense now. Have to remember this for the next time it comes up. No wonder you were asking about whether to tighten the springs all the way down. The stack was too big the other way.