My 86 Savage was bought used so I have no idea if the clutch was ever worked on, but the odometer have less that 9,000 on it when I got it (not sure how accurate it was, bike was a salvage title).

Last year I started to get the 3rd/4th gear WOT clutch slippage so I went for a full clutch discs and spring replacement.  

I soaked the discs in oil for a few days and then installed them.  Installation was pretty easy and straight forward.

When I went for a test drive I was slipping in all gears at WOT.  I thought that something might have been loose so I re-installed everything.

It's a little better now, but it's still slipping at WOT in 3rd and 4th.

I'm hoping that it just has something to do with soaking them too long (directions said for a few hours) and I just have to wait for it to for it to wear off.  I'm using Honda 10w-40 motorcycle oil.  I have also adjusted the clutch lever several different times to see if that makes a difference.

Any suggestions?

you could a little more spring presure with washers - could be caused by wear to the clutch basket - if any groves have worn into the surface of the slots the plates can hangup a bit

When you buy the washers, take a calliper along. They vary in thickness quite a bit. Also, you will see a milled spot where each spring sits. Close inspection will reveal thay are different depths, so, I cut the OD of the washers to fit inside the relieved area. Easy to do all at once, by putting them together on a bolt with nuts top & bottom to squeeze them together, stick it in a drill press & turn it on, then run a grinder on the washers as they spin. A friend holding a drill, or sticking the drill in a vise, OR, last resort, set the trigger & step on it, bend over & grind away.

Nope, no pressure plate, just the discs.  At least the EBC kit I got from Dennis Krk only came with the clutch discs.  I'll give the Suzuki dealer a call tomorrow.

Generally speaking, when swapping out friction plates I would always hit the re-used steel plates with a bit of 220 wet or dry paper just to lightly break up the glaze on the drag surfaces.  Bet you got some slicky surfaced steel plates that aren't doing very much with the rough irregular fresh cork surfaces on your new cork plates.

This also removed any protruding wire edges on the steel plates for the next step, which was checking them for rock  or cup (warp & flatness) on the formica table top in the kitchen.  Got to check on both sides to see both of these potential issues.

If cork plates measured clearly within spec but both steel and cork appeared glazed from slippage, I have lightly sanded both mating surfaces and put the roughed up corks and steels back in until I could order up the new corks and get them shipped in (I reused old side cover gasket with some silver Kawasaki Bond sealant).

I have run that way for a goodly while on one old CB160 honda as the gooped up side cover gasket didn't leak and the clutch stopped its mess for nearly two years just from roughing up the plates good.  

Ah, I was young and broke back then -- I have more money now and generally plan major replacement stuff ahead of time now-a-days.


Oldfeller

Any updates?  What happened?

did you check over the basket? should not be any groves worn on the edges of the fingers

Reelthing wrote on 05/06/08 at 20:11:51:


I gave it all a one-over at least 3 times and I didn't see anything out of the ordinary.  Of course i'm not an expert.

The springs and fiber plates are brand new from EBC.  The pressure plates are new OEM from Suzuki.  It has gotten better so i'm just going to keep an eye on it.  I may try a different type of oil eventhough i'm using 10w40 Honda motorcycle oil.