Intermittent Clutch issue

[Rasputin]

I have an intermittent clutch problem going on with my 78E. This is the strongest ride I have ever had on an XS11. I can go out for a ride and hammer on it all I want and it acts fine. The next ride the clutch will slip enough to send me home worried that I broke something. I can get the front wheel off the ground on straight acceleration from a 5 mile an hour roll. The next ride it will slip at 4000 rpm or hold on till it hits 7000 rpm before it slips. The problem seems to manifest itself in all gears and situations. Sometimes it is a momentary slip and other times it just seems to let go and won't hook up again until I throttle down.
I have a new clutch handle, good free movement of the cable which is freshly lubed, properly adjusted at the bars and clutch, new heavy duty clutch springs, Steels and fibre discs all within specs. I have done the adjustment at the clutch itself a couple of times to see if that makes any difference, while following the proper procedure for doing so. I am running 20-50w dino oil which does not have the friction modifiers. When I bought the bike the clutch would slip every time I tried to go over 4000 rpm. I tore the clutch down found everything in spec, cleaned the steels, replaced the springs and put it back together. The clutch cable was almost frozen solid so I worked it and lubed it until I have it moving as freely as a new one. The only thing I can think of is that the fibre's were glazed from previous slipping. I plan on ordering new clutch fibre discs but was wondering if anyone had any other ideas that I may have overlooked or ideas to safely remove any glazing. Any input is always appreciated.Thanks.

[Ken Talbot]

I have done the adjustment at the clutch itself a couple of times to see if that makes any difference, while following the proper procedure for doing so.

As a point of reference, that is the ONLY way to adjust the clutch. It is a very finnicky adjustment, where the slightest amount of a turn too much or too little will throw it off. Anything you do at the handlebars is simply adjusting the amount of cable slack. It almost sounds like you might be just a hair too loose on the adjustment, and that hair would in fact be blond rather than brunette.

[Rasputin]

So I may have turned the adjuster back too far or not far enough? I have tried 1/8th turn to 1/4 turn back on the adjuster and it seems to stay the same. Should I try just backing it off a 1/16th of a turn or is that too close?

[Ken Talbot]

Wherever it is now, which is where you are experiencing just a bit of intermittent slippage, I would try backing it off a "blond hair" more, say another 1/16 or maybe only 1/32 of a turn or so. Don't run it all the way back in to the contact point and out again, just go a bit further out.

[gonzo]

I had the same issue and it was just finessing the adjuster too the right spot. Its hard to get it locked down in the right spot when your kids use your tools for hammers and chisels...

[natemoen]

I thin I am getting this same problem but I am just starting to get her on the road so it could be other things for me.

[Rasputin]

I was just thinking, would it make a difference if it is adjusted when engine and tranny are hot or cold? If so should it be adjusted cold only?

[Rasputin]

I did a small adjustment as advised. Took the bike on a hundred mile ride. I was in town on major highways and in some cases over 100mph. It only slipped briefly twice during that ride. maybe just a smidge more tweaking and I will have it. Wish me luck

[DGXSER]

Luck....but only the good kind!!

[Montreux_Blue]

I've had a similar problem and turned the set screw at the clutch a full 1/2 turn back and have never looked back....