Hi - I'm having a nightmare with the clutch on my 86 savage. Clutch started slipping under 2 up acceleration and at the top end. So I thought I'd treat it to a new set of EBC springs and plates (EBC springs 15% stronger than standard.
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.
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?

rockabilly wrote on 10/12/15 at 11:51:22:

You took the side cover off to adjust the cable?
Quote:

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.

Sorry responses getting out of synch as my link is playing up.
No didn't take side off to adjust cable - I knew there was a mis-assembly as there was way too much cable even with both adjusters screwed out to their max (engine and lever). So side off to identify the issue.
Good idea to do it on the bench and then bolt down. I'll give it a go tomorrow! There's def something amiss as with no springs I would have expected the clutch to spin quite merrily when I put a spanner to the clutch nut but it doesn't everything is locked up tight

Yep everything sitting where it should (well apparently something isn't!!) but all teeth are cleanly meshed where they should be and the clutch basket is sitting cleanly on the splines

Think that's the thing to try............ 2lb or 5lb hammer???!  

Don't be shocked if the throw out breaks again. They have been known to break with a stock clutch. When I did the cam I shimmed the springs with one, normal sized washer under each spring. Mine broke a year or so later. They are made of sintered metal, the OSB wood equivalent. Just heated, pressed powder.
verb
past tense: sintered; past participle: sintered
make (a powdered material) coalesce into a solid or porous mass by heating it (and usually also compressing it) without liquefaction.

If I intended to keep the bike, I would've looked into having one machined. When it goes, if you're halfway through a gear change, it's liable to break the cam chain guide where the tensioner mounts.
Mine did. I wasn't riding it, so, exactly what happened, I don't know, because the guy who was riding it lacks sufficient mechanical understanding to really explain, and, if he told me the sky is blue, I'd hafta go look, just to be sure. If you get my drift.