Upon getting it home and opening up the clutch it was apparent that it was fried. He has another EXP on the way from Rekluse (it was still under warranty) and he bought new Tusk clutch plates. We put the new plates in yesterday with no Rekluse planning on riding with a regular clutch today, but we could get no feel at the lever. If you pulled it in it would just stay in. It was actuating the push lever (# 21), but the lever would just stay wherever we put it. We pulled the clutch apart and inspected the plates (# 7, 8, and 12), bolts and springs (#9 and 10), pressure plate (#6), clutch basket (#4), push rod 1, bearing, plate washer, C-clip, and push rod 2 (# 15, 16, 17, 18, 19, and 20). All of these seem to be in good condition.
We did figure out that if we have no plates in the clutch that we could get feeling at the lever because the pressure plate (#6) would be closer to the plate washer (#17) and the little bit of action that the push rod has was enough to move the pressure plate. With all of the clutch plates in, the pressure plate was too far from the plate washer and they would never contact each other when pulling the clutch lever.
We did measure all of the fibers and steels to make sure they were in spec even though they were new and they were.
Any ideas? We are at a dead end and don't know what to try next.
Edited by woods-rider, November 25, 2012 - 06:09 PM.