clutch slipping everything looks fine

[Bigdong]

Hi everyone,

Basicly the problem ive got is my clutch cable seems too short, its adjusted as long as i can make it but its only juist bitiing when i let it out so once i apply some power the clutch slips.

Ive checked the plates and they are within spec and ive also measured the springs and they seem fine aswell, though i have oredered some new ones just incase. The only thing ive noticed is my friction plates are warped. Could this be the cause of my problem?

thx

[Kaw_04_250f]

So do you still have some free play or slack in the cable or is it still tight after you have adjusted it? Have you also adjusted the cable adjustment or just the one on the perch?

[Bigdong]

Hi, yeah I've adjusted both the perch and the one on the engine but the cable is still tight.

[cereal killer]

Can you take a picture of this part on your bike?:

With the cable detached, how far forward can the lever go before there is resistance?

I can't see the springs being the problem. If they were worn out they might cause slipping, but it wouldn't make the cable too short. It sounds like there must be something wrong with how your cable is attached.

What year is your bike?

[Bigdong]

It's an 09 , I cracked the cases at the end of the year and just rebuilt it so could be something I've done on the rebuild. Will get a photo later today.

[Bigdong]

I was thinking maybe a combination of warped friction plates plus worn springs might mean the arm is not being pushed back enough and making the cable shorter.

eDIT:- Forgot , ive already taken the whole clutch bvasket out so cant et a photo of that under pressure. I will rebuild it tomorrow and check to see where its at and take a photo.

Edited January 14, 2013 by Bigdong

[cereal killer]

The springs are pretty heavy duty and the pressure needed to hold the pressure plate down is minimal. Your springs could be too weak to hold the plates together (causing the slipping), but that wouldn't explain why your cable seems too short.

It almost sounds like the opposite problem. e.g. the presure plate is pushing the push rod too far. But that seems much less likely than a problem with the way your cable is adjusted.

If you disconnect the cable from the lever in the picture. Is there any slack in the lever?

[Bigdong]

Took a photo today, This is as far as my cable will go.

[grayracer513]

The release arm looks like it's being pushed all the way back against the crankcase in the picture. With the cable disconnected, the arm should be free to rotate about 5-10 degrees either way with no resistance to speak of. If it isn't, the problem is in the way you stacked up the clutch assembly; no internal free play.

[Bigdong]

The release arm looks like it's being pushed all the way back against the crankcase in the picture. With the cable disconnected, the arm should be free to rotate about 5-10 degrees either way with no resistance to speak of. If it isn't, the problem is in the way you stacked up the clutch assembly; no internal free play.

It does have free play, thats me just pushed it up to where there is resistance. so you can see how the cable is not reaching.

Its like im about 1mm too short with my cable, or something inside has worn.

Edited January 17, 2013 by Bigdong

[cereal killer]

That does seem a bit far back, but doesn't look like it's hitting the cases like in my picture. Even if it is a bit far back, your cable should be able to adjust that far. It worked normally before you took it apart right? Have you adjusted both the perch adjuster and the in-line adjuster on your cable?

When you loosened the cable off to disconnect it, it could have popped out of the perch too. Make sure it's inserted properly at the lever end.

Edit: not sure if that was a good description. I'm referring to this part of the cable:

Edited January 19, 2013 by cereal killer

[Bigdong]

yeah ive checked the perch aswell , its sitting all the way in except i have mine screwed right the way in to get as much length as possible. ive got new springs now so im gonna pop them in and go out for a blast today. will let you know how i get on.

[grayracer513]

Are you aware that there is a mid-cable adjuster about 3 inches out from the lever under a rubber boot?

[Bigdong]

Are you aware that there is a mid-cable adjuster about 3 inches out from the lever under a rubber boot?

Id have to check, i think thats adjusted but today when i was out everything was going fine and then clutch started slipping untill it dissapeared alltogether. Now when i have removed the cable the lever has no free play and the only thing that stops the arm is the casing.

Also once the clutch went the casing was absolutely roasted so i took the clutch apart at the track and it was smoking it was so hot.

Edited January 19, 2013 by Bigdong

[Bigdong]

Im suspicious that my plates are actually worn and possible my inner basket too but i cant find in the maual any meaurments for the basket. Can anyone tell by these photos if this is a badly worn basket?

[cereal killer]

If you try and ride it when it is slipping it's going to burn your clutch in a hurry. The pressure plate looks fine, the boss (second picture)... not so much. Looks like you have some pretty significant grooves forming from where the drive plates make contact. However, that does not explain what is causeing the clutch to slip or why the arm is pushed so far back. It seems more likely that it would cause your clutch to not release cleanly.

It still seems the problem has to be with the cable. But, if it was a problem with the clutch assembly, it has to be something causing the pressure plate to be pushed too far down against the push rod... and I can't figure out what would cause that (unless you have switched parts with another bike?).

[grayracer513]

I can tell you that neither of those parts are a clutch basket, but they are both worn on the face that the plates run against. The top pic is the pressure plate, and the second one is the clutch boss. This could be a part of your problem, but check that adjuster anyway.

[Bigdong]

I put a new apico clutch kit in and got someadjustment back bbut within one ride I'm back down to Clutch just wanting to slip and absolutely no free play. my cable is at its longest , I soaked plates for 24 hrs so only thing I can think to do is add an extra pressure plate in the middle to give me the extra play that I need.