Hello,
I am attempting to rebuild my clutch I have fitted new fibre disks, plates, spring, & spring nut. The old spring was not lifting straight & measurements confirmed this. The new springs measurements are within range given in the technical section/ clutch problems. In fact I have followed all the steps in this document. I have fitted a shim under the spring nut, & machined the clutch center to within .005. I have made up clutch push rods of varying lengths in an attempt to make sure the clutch center is rising to the maximum height. The problem I am having is that the clutch still lifts unevenly and will not disengage the plates, all surfaces in the center, & basket are smooth. I have omitted one fiber disk, & one plate. If everything checks out why is it still raising unevenly? I should also add that what led me to rebuild was the clutch would not disengage sporadically usually after things had a chance to heat up. I also developed a metallic knock that you could feel coming from the push rod/operating rod area. This would go away if the adjustment was backed off but then you would lose clutch disengagement. If I fit a shorter push rod it does not make this noise, but then it doesn’t lift the plates high enough. Any thoughts would be welcome as I think I have covered everything I know to check.
If the clutch raises unevenly then you might want to take off the inner cover and watch what happens when you pull in the clutch lever.
Basically, IMHO, the only things that can go wrong are if the inner edges of the plates get stuck, or if the outer edges of the plates get stuck, when you activate the clutch. Look carefully - if you can see where that's happening mark the place, dismantle the clutch, and examine very carefully for any burrs or tightness that could be causing it.
I've no precise idea what the knocking might be, but I'd venture that if your clutch is disengaging unevenly then some part of the plate assembly will be fouling some part of the basket as it turns.
Hi Allen,
Thanks for your response. This morning a reassembled the clutch using some of the original fiber disks & one of the too thick repros I was trying to use before. I was able to get the clutch to disengage & engage. So I went for a ride. Everything worked well. Later in the day I went to restart and the clutch would not engage or disengage. I re-adjusted the clutch lever & everything worked fine. Went for a ride and the clutch was dragging then would not engage or disengage. I should also add that I left the chaincase & clutch dome off the whole time so I can watch how the clutch raises. I have also polished all surfaces and followed Ians instruction to the letter. I`m going to try purchasing a new set of clutch discs from Ian and see if this makes any difference. It has to be something to do with the size of the stack & the length of the clutch rod. I just cant seem to get them both right at the same time.
I'm still learning on these bikes but have you got any play/float in the whole clutch assembly? I read in previous threads on here that some owners had a lot of 'slop' with up and own, side to side movement of the complete unit. Maybe you have the same? This might account for account for it? This, from how I read it, is down to a combination of clutch centre, rollers and /or chainwheel wear. If the whole lot is moving it might explain the difficulty in getting the balance of adjustment right between rod and plates etc.? I didn't notice your symptoms but I did have a huge amount of play on my unit - but the centre part bolted up nicely. Only replacing those parts cured it.
Hello,
I checked the clutch hub nut, & it is done up tight. Also any free free play on any of the parts has been corrected. I am going to try fitting all the original disks & push rod back on to try & see if I can get it to work. Might even go back to using the full stack of disks & see if I can keep it in adjustment. Thanks for all the suggestions they help me to go back through the process & recheck everything.
