Anyone know what the pressure plate travel is supposed to be?
I have owned this '03 WR450 for about a month. Its been cold here and I have never had the bike above 140 degrees. Finally yesterday I got in some traffic and the coolant temperature rose up near operating temperature. At 180 degrees I began to notice that the clutch was not fully disengaging. I had to use the brake to keep the bike stopped. At 190 degrees it was really pretty bad. At that point the shifts in and out of neutral were harsh. I came home and read all about the washer modifications and so on. So tonight I decided to do the first oil change on the bike and open up the clutch cover and see what was going on. I watched the spring as I worked the clutch and the spring did not appear to bottom out like suggested by some people regarding the washer mod. I measured the clutch handle free play to be between 11.8 and 13mm, which is upper range of in spec according to the manual. Now this bike appears to have aftermarket clutch and brake handles so I was not so sure I could trust the geometry of the handle to be the same as stock. So I decided to remove the doubt by measuring the pressure plate travel. I measured the travel to be between 0.037 and 0.041". I then adjusted the handle to basically remove all free play and found when I did this I get between 0.058 and 0.061" of pressure plate travel. Even with no free play, the clutch bottoms out on the grip when pulled. Is this normal or should there be a stop that prevents this? Again I am curious because of the unknown of my handles.
So I am wondering if anyone knows what the travel is supposed to be?
I suspect this was my issue and maybe I don't need to do the washer mod. Thoughts?
With no free play, the clutch handle is pretty far away from the handle bar and not all that comfortable.