Clutch replacement

[jetmechmarty]

Did you start with the adjustment UNDER the cover? Loosen the 12mm lock nut, turn the phillips head in till you feel it drag, then back off 1/4 tune and tighten the lock nut. Do this with the clutch cable very loose, like it will not engage. When done, you then adjust the clutch cable for about 5 to 10mm play at the end of the lever before it starts to pull.

That’s exactly what I did.

[jetmechmarty]

Not sure this is a materials issue. The clutch seems to be binding and has a fair amount of drag so the gearbox does not shift smoothly. It's not fully releasing when the lever is pulled in. It could be the assembly binding on the "fingers" of the basket. It could be the pressure plate "star" binding because the springs were tightened slightly lop-sided. It could be the stack of plates and pads are out of sequence. You'll find it. Gasket should still work as it's only been one ride.

Yes, I’ll start here.

[bikerphil]

Yes, Vesrah.

Just saying, they have been reported to cause a binding issue and not fully releasing. I have never used them personally, but just going from what I have read.

[Larrym]

Dayum.... ( ͡° ͜ʖ ͡° )

Looks like it's time to get all workbench "Sciency" on those frictions, steels, and springs. (Θ︹Θ)

I've NEVER been able to detect/find warpage in the plates by eye... (•﹏•╰)

Always had to use a feeler gauge to find it... like seen HERE at time 17:54-

Diagnostic Powers ACTIVATE! (^_^)

[cajun31]

Marty, Not knowing anything about how you actually approached this I am going to ask a question or two. Did you soak your new frictions in oil overnight before installing them? What was wrong with your old frictions? Any noticeable damage or wear? If not a good test would to be put those back in. The new springs will solve slippage problems if the frictions were still in good shape.

[jetmechmarty]

Marty, Not knowing anything about how you actually approached this I am going to ask a question or two. Did you soak your new frictions in oil overnight before installing them? What was wrong with your old frictions? Any noticeable damage or wear? If not a good test would to be put those back in. The new springs will solve slippage problems if the frictions were still in good shape.

Yes, I soaked the new frictions in engine oil overnight. I simply assumed the clutch worn out. Step next, I will measure the old plates against the FSM.

Thanks.

[bikerphil]

It feels like the stack is too tall

You may be on to something here. Interesting to know what the Vesrah measures compared to your original frictions. I have a new Japanese made partsNmore friction here. I will check the thickness and report back.

[jetmechmarty]

Thinking about this. The bike moves forward with the clutch pulled to the grip. The clutch also slips when power is applied. I think maybe the ears on the friction plates are too snug. They didn’t fall into place on assembly. I pushed them into the basket.

No too long ago, I put an Alto clutch in a XS650. Those were thinner friction plates allowing me to go from 6 to 7 plates to cure a slipping clutch. Those plates fell into the basket.

[bikerphil]

I think maybe the ears on the friction plates are too snug. They didn’t fall into place on assembly. I pushed them in

That doesn't seem right, they need to slide freely. Here's the measurements from a new PartsNmore friction...