Hi all!
The question is: when do you know that your clutch plates need replacement?
This is my situation..
When I bought the bike this summer, it was a bit hard finding neutral. .  I must replace the famous thrust washers and do the clearance basket procedure. I was planning to do this during the next oil change. The problem is, that during the last couple rides (hot weather, hard off road driving), it is also quite hard to shift from 1^st to 2^nd and 3^rd .. So I’ve decided that I have to work on the clutch ASAP… I will change the washers, do the clearance, and I was thinking if I should change the plates once there too..
And if so, do I have to change the complete set, including the steel plates and springs, or just the friction plates will do the work?
What is that generally causes this hardness during shifting?
Thanks!

Check you basket, you want to carefully File down any notches or groves in the finger type section. Also slightly file down the squared of edges of the same areas. This should greatly increase how smooth and easy you go from gear to gear.

Thanks for the answer Dentman!
So it shouldn't be a problem of plates you say?
When I first bought the bike, I had opened the clutch, and measured the plates, and had seemed in specs.
I didn't have at that time the thrust washers to replace them, and I did some of the filling and clearance too, as you said, but it seems not enough.

I would just replace the plates and disc at the same time.  not like you are going to save much money not replacing everything.  Also make sure your cable is in working order.  A dirty cable can make it so the clutch doesn't fully disengage correctly..

Hi again!
So today I decided to open the clutch, change the thrust washers and do a bit of clearance on the clutch basket!
When I had opened everything and was checking the things in there, it came to my mind to go check the clutch of my DR250S '91, to see if the parts were in better shape, to use some of them instead.
Well this is what I found out! the previous owner, one of the many, had used an extra washer, to create the clearance needed.
This is it, and where it must have been positioned


the washer measures 25x21x2 mm and creates a gap of 1.5mm approx, so the basket can turn without problems!
This is what it looks like


I have to say that I've never experienced any problems with the clutch of my DR250S
and now I believe that this washer is the reason! So I am thinking to use it with the 350 as well,
without doing any clearance at the basket.
I will only file down the notches in the fingers, put the new thrust washers, and install everything back!
What do you guys think? Any objections??
Thanks!

P.S. Thankfully the shift drum bolt was firmly in place!

Edited by pavlos79, 12 March 2012 - 11:51 AM.

Come on guys,
I would like to hear your opinions! this is the most common issue the DR350 has..
I would like to try it, since it was installed on the 250 and it worked fine, but I am also a bit hesitant not to do anything really stupid, and mess up the engine
Objections anyone?

If the washer definitely an extra to the DR250 clutch assembly, and it worked well, then I'd say go for it. You can always take it out again if it sounds/feels wrong.

Geoff

I'd give it a try.

Well, here is how things went!
Saturday I finished doing the clutch maintenance job!
I filed down the notches from the fingers, I replaced the famous thrust washers
AND I installed the extra washer as mentioned above!
And it worked!!!
Yesterday I took it for an off road ride, quite hard for the bike, snow, trails, mud etc, and I am so impressed!
The shifting was  smooth and neutral was so easy to find,
I do not know if and what will be the consequences in the long term.. I hope that there won't be any!
Since it was installed on the 250 for more than 2 years without any problems, I hope it won't create any at the 350 as well.
One thing I noticed is that the extra washer leaves a couple of less threads available for the clutch sleeve hub nut.
But I tightened it to the specific torque (60Nm) I locked it bending the lock washer, so I hope it will not create any problems!
Maybe it is early to call it a victory, but the initials results are encouraging!
I will let you know if something bad happens in the future!