digging into the tranny

[adam79]

?

I took my clutch apart today. Not what I expected. There were 9 steel plates and all 8 friction pads were between 2.4mm-2.5mm. This is my first time viewing these parts (not new out of a package, but old out of the bike) and they dont resemble any pictures I've seen. The friction plates were all dark red, and the steel plates all have a worn copper-ish glaze...all 9 of them, haha. Then, as I was looking at the part catalog, the clutch boss assembly has a total of 3 plates (seat plate, cushion spring, plate) and then the retaining wire ring. When I look at my clutch boss assembly, it does not look like I have all these parts.

1: Should I take the ring off and check? Can you guys tell from looking at it?

2: Is the discoloring on the steel plates normal, or should I replace them all? (just 7, not all 9)

[bikerphil]

discs

The service manual states the friction disc thickness should be not less than 2.8mm. The metal clutch plates can be checked on a piece of plate glass for warpage. The tolerance is 0.1mm. If they check out ok, use fine grit sandpaper to remove the glaze. New clutch discs at Partsnmore.net are the cheapest price wise that I've found, and I've been using them for years with no problems.

[adam79]

so this wear Im seeing is all normal then?

[trbig]

Hmmmm...

I'm wondering if someone thought that if ONE extra steel plate was good, two would be even better when it started slipping again?

I have never seen that kind of wear, or that color on the plates. I have never wore one down enough to see if that silver color on them is copper underneath?

I, personally, would hit people up for the steel plates, and order 8 new friction discs... then install new springs. Again.. I PERSONALLY would also slip one extra steel disc in there.

I have no experience with the problems Ray explains with adjustment of the clutch after installing an extra plate. They have always adjusted easily for me.

Tod

[adam79]

I have bought all new friction disks and springs to replace the old, so maybe I should just get new steel plates as well. I dont have a sheet of glass per say, can I just hold them up to the living room window? Also, does it look like I have all the plates to my clutch boos? It doesnt to me, so maybe that is why there is 9 steel plates in here.

[boyat68]

A mirror would be sufficent to check warpage. The idea is to have a level surface that you can view to see if the warp is greater than 0.1 mm. Most homes have a flat mirror that can be taken down off of the wall to use. If this is not possible then many homes have electric or gas ovens with a view window that can be laid out flat.

[trbig]

No, you have all the parts there. That exploded view you showed has an assembly listed as #8. The last piece in that assembly is #11 held in place with the wire (#12)... of which you show in your last pic. What you have with the 9 steel discs... is simply a story for the "What PO's did to your bike" threads.. lol.


Tod

[bikerphil]

Yeah, I guess the window would work, never tried it though. If you have the new frictions, you should be using 7 steel plates in between the discs, and the 8th plate is fastened to the outer clutch boss behind a spring clip. Assemble as in the diagram you posted. The 9th steel plate was probably in there due to under spec frictions, just to make it not slip. PO probably didn't want to spend the coin for new frictions.

[adam79]

Actually, if you are counting the plate in the boss assembly, there is 10 steel plates totall.

[bikerphil]

Looking at your diagram, there should be 7 steel plates (part# 7), and 1 that's attached to the outer boss (don't remove this one), part # 11. No steel plate against the inner clutch boss.

[adam79]

Looking at your diagram, there should be 7 steel plates (part# 7), and 1 that's attached to the outer boss (don't remove this one), part # 11. No steel plate against the inner clutch boss.

Yes. There is supposed to be exactly what you said.

On my clutch: Part #11 is still attached to my outer boss, but as for part # 7...I have 9 of those total.

[prometheus578]

I got confused with the whole "counting the disks" thing, so I won't address that.
Hard to tell from the pics, but that coloration on the steel plates looks like normal burning. Not that burning is normal.. that's what happens when friction plates and steel plates "slip". Like BikerPhil and others have stated, just clean off that "high speed glazing" with sand paper or something.
I'm not a big fan of mirrors (for several reasons), but yes, you can use the living room window to check the steel plates for warpage. This has the extra benefit in that, if you move the plate around while measuring it, your neighbors across the street will think that you're waving at them, and they might stop saying bad things about you.
Set the plate against the window and see if you can slide the recommended feeler gauge underneath it.
Again, make sure to soak the new friction plates in oil for several hours to allow them to absorb some oil, or they'll glaze up pretty quick when first used.

[bikerphil]

but as for part # 7...I have 9 of those total.

Use only 7 steel disks (#7) with new frictions and of course the one #11. No need for extras.

[adam79]

Set the plate against the window and see if you can slide the recommended feeler gauge underneath it.

I understand how many of which plates I need. Sorry for the confusion. As for the gauge..if I can slide a feeler gauge under the plate that is larger than the recommended size, is it time to buy new ones?

[bikerphil]

the 0.1 mm feeler gauge is equivalent to 0.0039 inches, so try an .004". It's probably one of the thinnest on the gauge. They should be only about $5 at a cheap auto parts store. A thicker one isn't any good. If the .004" gauge won't fit under any part of the disk while resting against the glass, then the discs are OK.