Problems with newly installed clutch plates?

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TheCrystalHammer
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Problems with newly installed clutch plates?

Post by TheCrystalHammer » Fri Mar 09, 2018 8:57 pm

Hi all,

I'm having some trouble with my new clutch plates (1986 XT600) I Replaced the friction plates and springs the other day, but now can't seem to get it adjusted properly. Essentially the clutch lever is SUPER hard to pull in now, the clutch wants to stay engaged (though I can adjust the cable so it's mostly disengaged) and at the same time the clutch is slipping when you drive up the road. Really weird. I'm pretty sure everything went in in the right order.

Oh, and the plate/parts diagrams for these clutches are not very good. Rebuild kits come with 2-2.8mm friction plates and 6-2.6mm friction plates. Right now I have the larger ones on either end and the smaller ones sandwiched in the middle. Could this be my problem? Tried several adjustments and have had the case off of this thing 5 times in the last 2 days and can't seem to figure it out.

One thing I did notice is that the push lever comp is pulled really far forward compared to my boyfriend's bike (1985 xt600) in order to disengage the clutch. What do you think? Do I just need to play around with adjusting the push rod screw more, or is it more likely something is out of order? I need to drive to Utah from Texas on the thing in a few days and need it to function!

Thanks

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Mezo
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Re: Problems with newly installed clutch plates?

Post by Mezo » Sat Mar 10, 2018 12:21 am

From memory the two smaller plates go on first followed by the rest, what oil did you use? semi or fully synthetic?

Also its recommended to soak the plates overnight.

Mezo.

TheCrystalHammer
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Re: Problems with newly installed clutch plates?

Post by TheCrystalHammer » Sat Mar 10, 2018 1:09 am

Oh interesting - the two odd sized ones are a bit larger but I'll try that configuration. I did measure the plates as I took them out but was a bit hard to read the manual micrometer. I'll switch them around and let you know how it goes. Soaked the friction plates in semi-synthetic for about 30 min before installing them.

Thanks :)

TheCrystalHammer
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Re: Problems with newly installed clutch plates?

Post by TheCrystalHammer » Mon Mar 12, 2018 9:22 pm

Daaaang Mezo, the next time i'm in the UK I owe you a beer! Problem solved... put the two larger plates in first and everything's a-ok. Thanks so much for the help!

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Re: Problems with newly installed clutch plates?

Post by jibber » Mon Mar 12, 2018 9:54 pm

Dont ya just luv im............................oh and hes in Oz

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Mezo
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Re: Problems with newly installed clutch plates?

Post by Mezo » Mon Mar 12, 2018 10:24 pm

TheCrystalHammer wrote:
Mon Mar 12, 2018 9:22 pm
Problem solved... put the two larger plates in first and everything's a-ok. Thanks so much for the help!
Glad i could help. :star:

Mezo.

TheCrystalHammer
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Re: Problems with newly installed clutch plates?

Post by TheCrystalHammer » Tue Mar 13, 2018 9:01 pm

My only problem now is that the clutch lever is REALLY hard to pull. Could this just be inevitable with new springs, or can I fix it somehow? My beau’s bike is the same but an 85 and the clutch is like butter. I’m jealous and my wrist/hand is going to get real sore quickly in traffic or on any sort of technical terrain. Clutch cable was replaced about 4 months ago.

We tried to hack it by removing the spring on the push lever comp on the top of the case where the cable feeds into (it’s broken on the other moto), but it’s not any easier.

Any ideas?

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Re: Problems with newly installed clutch plates?

Post by Mezo » Tue Mar 13, 2018 10:31 pm

Was there any wear on your clutch basket "fingers" like grooves worn in? this is not an XT just using it as an example.
Im not saying this IS the cause, it could be like you say new springs, you could put the old ones in & see if its easier.

Image

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Re: Problems with newly installed clutch plates?

Post by GeoffD » Wed Apr 04, 2018 2:42 pm

TheCrystalHammer wrote:
Mon Mar 12, 2018 9:22 pm
Daaaang Mezo, the next time i'm in the UK I owe you a beer! Problem solved... put the two larger plates in first and everything's a-ok. Thanks so much for the help!

Sorry chaps, but the 2 plates with the larger diameter holes do NOT go in first..

one goes in 2nd (to accommodate the wave plate) and the other goes in last..... do not try to use your bike with both large plates in first... :nono:
The future is not what it used to be....

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Re: Problems with newly installed clutch plates?

Post by GeoffD » Wed Apr 04, 2018 2:43 pm

TheCrystalHammer wrote:
Tue Mar 13, 2018 9:01 pm
My only problem now is that the clutch lever is REALLY hard to pull. Could this just be inevitable with new springs, or can I fix it somehow? My beau’s bike is the same but an 85 and the clutch is like butter. I’m jealous and my wrist/hand is going to get real sore quickly in traffic or on any sort of technical terrain. Clutch cable was replaced about 4 months ago.

We tried to hack it by removing the spring on the push lever comp on the top of the case where the cable feeds into (it’s broken on the other moto), but it’s not any easier.

Any ideas?
Yes, see my previous answer.....

You have actually refitted the wave plate I hope??
The future is not what it used to be....

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