rockabilly wrote on 10/12/15 at 11:51:22:Straightforward replacement bolted it all back up and found I had far to much cable play, whipped the side off again, plates out, plates in reassemble and everything seemed fine.
You took the side cover off to adjust the cable?
Quote:Side on - pulled in the clutch lever .........SNAP..no clutch :'( Side off and it's snapped the clutch release cam! So while I'm waiting for a replacement (from the US) I look at the clutch and with no springs putting any pressure I would have expected there to be a bit of play between plates - but with the clutch nut torqued up to 60n-m everything is rock solid - and I don't think this is right ..is it?
Don't want to wait for the new unit only to stick it alll together and snap it again! Any advice have I missed something?
You need to check the protrusion of the clutch throwout rod.
I generally set as close to 12.5mm as I can, and have made Half size rods to do this. (rather than increments of 1mm, 0.5mm)
This will get you into a sweet spot on actuation.
I also noticed the corners of the rod get a burr so I grind a full radius on them (this does shorten them a bit)
The full radius fits better in the throwout cam.
Next, the clutch pack can easily get off center when assembling as installed.
I think it's the wave washer that gets mislocated and jams.
If you do it on the bench, then lock it up with the springs before putting it on the bike, I've had no problems.
install at least 2 opposing springs with a washer and the bolt.