How much slack was in the clutch lever before the clutch bit th weenee?

Oldfeller--FSO wrote on 09/01/13 at 19:15:34:


Well.....I might be a bit late to this clutch party!

I wasn't delayed getting my bike back together....but the EBC spings made the clutch slip.  The parts that EBC has listed for our bike is wrong, and the springs they list are actually weaker than the stock ones....and the clutch slipped with even a light throttle.  I took the cover off and put the stock springs back in.....and it worked.  This wasn't all bad....it made me have to be gentle on the new piston and cylinder bore for a while!  I contacted EBC and eventuallly they got me the right springs....but I am not sure they are convinced and changed their catalog yet.  I have not installed the EBC springs as the stock ones are working fine.  I can supply the correct numbers once I go home and check the numbers.

I am not entirely sure what happened to the clutch in this topic.  Kizale  stalled and restarted and had trouble getting the bike going....then the trouble showed up.  It may have been that the clutch damage was done in this one incident if the cltutch was abused....with our without the wrong oil or additives.  The first photographs of the clutch don't seem to show the horrible burned plates that are seen in the photos after the clutch rod incident.  (If I were to speculate........and please don't take offense Kizale as I am trying to help.....but do you know what a slipping cutch feels and sounds like?  Is this our first bike.....are ou a new rider?)  I might think that the clutch did not have adequate free play and the clutch slipped badly during the "stalliing in traffic" inciident.....and may have overheated the clutch and the damage begain.  The damage was then completed after the "too long" rod was installed.

Where do you live Kizale?  There might be a forum member in that area that can help with the clutch repairs?

 

Any other tips for getting it back together,I'll soak the disks first. Does anyone have torque specs?

Still having problems unfortunately.  I did get a clymers and new clutch parts. I used the steel discs from a forum member and new ebc discs. I installed everything according to what I read , everything fit together nice no leftover parts or anything silly.I connected the cable , filled it with oil and fired it up. The problem is it will not work when I pull the lever. It has good tension on it but would not go into gear. Shut it off and with the bike in gear and clutch in it will not roll. I took it apart again and reinstalled with the used stock discs I got along with the steels and same problem. I also checked everything when  I did it again and with the same result I can rule out ebc disks as a problem. With the pressure plate off the clutch assembly(inner, disks and outer will move back and forth together in the clutch basket. With the springs and pressure plate on it is firmly held in place. The 45mm rod put the lever right in the middle of the index. Any suggestions on what to do from here?

The lever does feel fine. With the engine off i can get it into gear but I will no roll with the lever pulled in. With in running it just grinds if I try to get it into gear. It seems it like it will not disenguage, the rod is in and the 45 puts it right between the index marks like it should.

I installed with the flat washer on the out side and the wave on the inner. the smaller diameter facing the outside and against the flat one, bigger opening aginst the first disc. Correct?

Any other sugestions?

Hmm the way I read it in the book was (starting outside and moving in towards the engine) Hub/clutch sleeve, seat/flat washer, wave washer/concave washer, disk 1. At this point I'd be happy to be wrong and have it fix the problem. So are you saying the wave washer should be between steel parts meaning, Hub, followed by wave washer and then the seat/flat to the inside of it, basically sandwiching the wave? If so do you also know which way to face the wave, I guess I could be wrong on that too. I had hub, seat, wave, disc 1/larger disk. It was sitting on disk 1 like this

 /   \
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Smaller part in on the hub larger opening on the disc, hope that makes sense, is hard to put into words.

Another thing I noticed is with side cover on, no oil, not running it won't move in gear, with lever in it does not want to move but with a little push it will then break free and roll. Does it need to be broken in at all. I only let it run for a couple secs and when it grinded into gear I fearfully shut it down. So it seems to drag like either it's getting fully pushed out or it could need lube, the longer rod however pushed it out of spec on the index. Maybe with oil in and running for a couple it will loosen up, or maybe the wave washer issue will fix it. I hope so, I think the next set if this doesn't work is setting it on fire.

Again thanks for all the help.  

I'll flip the wave washer tonight and see what happens. According to the book it looks like the seat should be against the hub