If I recall your bike correctly, you have some kind of aftermarket muffler as well.  The #200 main should work well.  In 20/20 hindsight, I think a #190 may have been a little crisper at higher rpm acceleration and maybe a little better gas mileage.  Either way, the Murray installed #165 with the e-clip in the 2nd grove is a pretty lean setup and gives up too much available power up top.

I have a complete clutch stashed away for a rainy day.  The fiber discs are almost worn down to the wear limit.  I don’t have the Clymer Manual in front of me, but the fiber discs only have like 0.1 - 0.2mm remaining before they hit the minimum thickness.  The fatter #1 fiber disc is the closest to hitting the wear limit (as I recall).  The main clutch components look good (running surfaces, measurements, etc).

Interestingly, Clymer doesn’t provide a spec for the steel discs.  This extra clutch I have measured right at 1.3mm for the steel discs.  Researching clutch kits on Amazon and E.Bay because OEM is so expensive, Caltric sells a kit (fibers, steels, springs) for like $38-$40.  They advertise the steels as being 1.6mm thick.  Without having OEM published specs (that I can find), I “assume” that 1.6mm matches stock new OEM thickness.  Assuming Caltric did their homework when designing the steels.

I know other people have installed the Barnett kit and are running without issues.  I hate to say it, but I think the installation orientation of the steel discs matters (cuz Barnett said so).  Maybe the “flat sides” bite more and the “rounded sides” slip/slide more.  Put 2 flats against a fiber disc and that fiber disc is probably getting bitten down on hard.  Meanwhile the fiber next to it with 2 rounded sides touching it, is slip sliding away.  (Just my uneducated arm chair engineering hypothesis and I could be wrong about which side of the steel bites/slips more, but they would have to behave differently since they are designed differently.). The fiber discs need a “biter” touching it on one side and a “slipper” touching it on the other side to create the optimal “even” friction on each disc.  When you take it apart, I’d be curious if some of the fiber discs are worn down and others are like new (or less worn down).

I hope this kinda makes sense.  I’m only on my 2nd cup of Sunday morning coffee.

Thumper

Solid f-ing call on the 200 main. The Murray set up was as you mentioned a 165.... And was on the lean side, for a long time. I'm going to change the needle position to your recommendation as well.

Appreciate you. Significant difference -- may lose MPG and I'm interested in checking the condition of the plug but I do have more power, that is a fact.

This week I'll open her up, check the condition of the clutch and likely throw the shorter rod in while I'm waiting on parts based on what's happening.

To be honest it actually feels like a different bike. I think the main kicks in after about 1/2 throttle pull-- I went into a roundabout and opened it up and  goosed it enough almost  to brake traction... Couldn't believe it. This is despite the clutch slip.

All good points thumper


Does anyone happen to know what the stack height of the pack should be with a fresh stock clutch? I have a nice micrometer that might be able to provide some insights here.

Philly, I provided all that info previously.  I think you should review the vids I posted in replies #82 & #91 before you dig into it.  You need to figure out what is preventing your clutch from engaging fully.  It sure seems to me that your pushrod is too long.  Excessive lost motion in your release cam is fooling you into thinking the clutch has correct free play.

The Barnett stack height should be the same as the stock stack height.  I suspect that is no longer the case on your bike since the clutch has been slipping.

When you get it apart, measure everything (steels, fibers, pushrod, spring installed height, spring free length, etc.).

Nope.  Listen to DBM.  This isn't rocket science.  You have been overlooking something and when you figure it out, you'll feel like an idiot.*  lol

*It's happened to all of us at some point and you're not an idiot.  But you'll feel like one.