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Diesel_Junkie

Adding an extra clutch plate, or swap for thicker ones?

13 posts in this topic

Has anyone added an extra clutch plate to an 07/08 WR450?

or

Tried swapping a thin clutch plate for a thicker one? There are 4 thick and 3 thin in the stack and the thicker ones are 0.4mm thicker than the thin ones.

I need to tune my clutch.

Clutch still works but releases at the end of throw, and I have run out of adjustment at housing and lever.

I took everything apart and all of it is fine and in spec. The primary, the plates, the cable.... everything.

Problem is not a stretched cable,,, its the opposite... the stack is getting too short(or so it seems).

So I am thinking that building up the stack a little thicker might help.

Thanks,

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I'm guessing that this is a dumb question ,but here goes any how. Did you use up all of the adjustment in the cable . you know there are 2 adjusters the fine thumn wheel and the course the adjustment tube is about 2 inches from the thumb wheel toward the center.

this one .

DSC00900-1.jpg

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I'm guessing that this is a dumb question ,but here goes any how. Did you use up all of the adjustment in the cable . you know there are 2 adjusters the fine thumn wheel and the course the adjustment tube is about 2 inches from the thumb wheel toward the center.

this one .

I gave his bike a once over last night and that second adjuster is all the way in.

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Yea,

both adjusters are completely collapsed. If I adjust either out a little i will get silppage.

Everything elses was torn down and measures in spec.

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that's weird I sware I've been adjusting both of mine out as it has worn down. are you sure the mount bracket is not loose on the motor or the push rod in motor is not messed up ?

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the pushrod looks new. I just double checked the cable stop and it's perfect too. I think I will compare the stack height to gregs bike, and buy another cable assembly, only $22

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The only thing that makes any reasonable sense is that plates are thinner than they were. That fits in with their behavior in so far as not catching until almost fully engaged. Nothing else fits the symptom set.

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My mate cooked his clutch up the dunes once and we had to back all the adjusters off so the clutch would grab otherwise it would have no drive. We took it home and with fine sand paper rubbed the steel plates carefully to take the glazing off and just cleaned the fibre plate in kero and it works it still works perfect a year later.

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The only thing that makes any reasonable sense is that plates are thinner than they were. That fits in with their behavior in so far as not catching until almost fully engaged. Nothing else fits the symptom set.

That is exactly what I thought, but all the plates measure like new, the steel and the friction plates.

I will do some more comparing to Greg's bike to isolate the differances.

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That is exactly what I thought, but all the plates measure like new, the steel and the friction plates.

I will do some more comparing to Greg's bike to isolate the differances.

leave my bike alone, mine works fine because I ride it right.... :lol:

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The ball is in the stack. All of that looks fine.

I made some comparison measurements to Gregs bike, Looks like it is most likely the cable housing that is messed up.

The cable looks to be 2-3mm too short, a short cable does not make sense... but longer housing might.

I ordered a new one.... no on has it in stock around here.

I will let you guys know if that fixes it....

Thanks,

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