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techtalk:evo:priclutch01 [2021/10/01 22:24] ixl2relax [Clutch Release Adjustment - Why & How] |
techtalk:evo:priclutch01 [2023/09/11 13:36] ixl2relax [Clutch Pack Stack Height] |
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| - | {{:techtalk:evo:priclutch:clutch-stackheight-chart.jpg?600}}((Annotated by IXL2Relax at the XLForum)) | + | {{:techtalk:evo:priclutch:clutch-stackheight-chart.jpg?650}}((Annotated by IXL2Relax at the XLForum)) |
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| * The "feel" at the release arm where the clutch cable attaches is very distinct so you have a high degree of confidence you got it right. | * The "feel" at the release arm where the clutch cable attaches is very distinct so you have a high degree of confidence you got it right. | ||
| * There should be some play at the release arm to assure there is no preload tension on the Diaphragm Spring & Pressure Plate. | * There should be some play at the release arm to assure there is no preload tension on the Diaphragm Spring & Pressure Plate. | ||
| - | * See this XLForum Post: http://xlforum.net/forums/showthread.php?p=5918480#post5918480\ | + | * **See this XLForum Post for a discussion of the adjustments:** http://xlforum.net/forums/showthread.php?p=5918480#post5918480\ |
| Now, go back to the Clutch __Cable Adjuster__ - Unscrew the two parts to lengthen the Adjuster just enough that there is still 1/8" of free play in the clutch lever movement BEFORE IT BEGINS TO ENGAGE THE CLUTCH RELEASE (check this at the cable connection to the lever) - Now tighten the Jam Nut on the cable adjuster and move the rubber boot back over it… | Now, go back to the Clutch __Cable Adjuster__ - Unscrew the two parts to lengthen the Adjuster just enough that there is still 1/8" of free play in the clutch lever movement BEFORE IT BEGINS TO ENGAGE THE CLUTCH RELEASE (check this at the cable connection to the lever) - Now tighten the Jam Nut on the cable adjuster and move the rubber boot back over it… | ||
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| This was to reduce the effort required to pull the clutch lever. There was also a change in the\\ clutch cable in 2007 to help reduce the clutch lever effort. | This was to reduce the effort required to pull the clutch lever. There was also a change in the\\ clutch cable in 2007 to help reduce the clutch lever effort. | ||
| - | | Notice the difference in the slots between the Diaphragm Spring fingers of '91-'03 and '04-later springs.\\ On the left is an '01 example and on the right is an '06 example. Both are 883 model springs.((http://xlforum.net/forums/showpost.php?p=4923807&postcount=7 - Graywolf))((http://xlforum.net/forums/showthread.php?t=49915 - CJBurr)) || | + | | Notice the difference in the slots between the Diaphragm Spring fingers of '91-'03 and '04-later springs.\\ Above left is an '01 example and on the right is an '06 example. Both are 883 model springs.((http://xlforum.net/forums/showpost.php?p=4923807&postcount=7 - Graywolf))((http://xlforum.net/forums/showthread.php?t=49915 - CJBurr))\\ Below are two more examples of diaphragm springs.((pic from IXL2Relax)) || |
| | {{:techtalk:evo:priclutch:clutch-assy-01-883-stock-graywolf.jpg?300|}} | {{:techtalk:evo:priclutch:clutch-assy-06-883-stock-cjburr.jpg?300|}} | | | {{:techtalk:evo:priclutch:clutch-assy-01-883-stock-graywolf.jpg?300|}} | {{:techtalk:evo:priclutch:clutch-assy-06-883-stock-cjburr.jpg?300|}} | | ||
| + | | {{:techtalk:evo:priclutch:clutch-diaphragm-spring-compare.jpg?600|}} || | ||
| ====== Spring Plate Failure ====== | ====== Spring Plate Failure ====== | ||
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| Some power shifting users take this opportunity to replace the stock Diaphragm Spring with one that is stronger. Others try to avoid making the clutch lever pull harder and may even install clutch release kits that ease the clutch lever pull. | Some power shifting users take this opportunity to replace the stock Diaphragm Spring with one that is stronger. Others try to avoid making the clutch lever pull harder and may even install clutch release kits that ease the clutch lever pull. | ||
| - | If you have an actual failure of the Spring Plate, with missing rivets having been strewn around the primary cavity, be sure to check everywhere those bits may have gone. The clutch basket may have been scored by the failure which will require careful filing to remove any burrs or, if bad enough, may require replacing the clutch basket. If not properly repaired, the new plates will not move smoothly to release the clutch engagement. | + | <font 14px/Arial> |
| + | **Repairing the Damage** | ||
| + | </font> | ||
| - | Also, the existing clutch plates (either steels or frictions) may have been warped during the failure. If the Spring Plate disintegrated, it is best to replace all the steels & frictions to avoild carrying damaged parts foward to damage new parts. You should also carefully check that the Pressure Plate & Release Plate have not been damaged, nor any other primary components (chain, sprockets, etc). | + | If you have a failure of the Spring Plate, with missing rivets having been strewn around the primary cavity, be sure to check everywhere those bits may have gone. The clutch basket is likely to have been scored by the failure. When the rivets fail, the spring strips that the rivets were holding will now slip out from between the steel plates of the spring plate. Exactly where the spring plate is located in the stack these spring strips make a gouge in the clutch basket (and in the clutch hub). This will require careful filing to remove any burrs created by the gouging or, if bad enough, may require replacing the clutch basket & hub. |
| + | |||
| + | Use a fine file and carefully check & smooth every finger of the clutch basket that has a gouge (see the pic below). You want to file the side and top corner where the finger is gouged. DO NOT FILE more than necessary to smooth that side face & corner. It is not necessary to remove the flat portion of the gouge from the finger. Due to the friction plate design, they ride on the sides of the fingers & not the top flat portion (this applies to the hub fingers as well). File off only enough metal for a perfectly smooth movement along the side face and inward corners of the fingers. **If not properly repaired, the new plates will not move smoothly to release the clutch during dis-engagement.** | ||
| + | |||
| + | Also, the existing clutch plates (either steels or frictions) may have been warped or otherwise damaged during the spring plate failure. If the Spring Plate failed, it is best to replace all the steels & frictions to avoild carrying damaged parts forward to damage new parts. You should also carefully check that the Pressure Plate & Release Plate have not been damaged, nor any other primary components (chain, sprockets, etc). | ||
| Here are images of the carnage resulting from the Spring Plate Failure:\\ | Here are images of the carnage resulting from the Spring Plate Failure:\\ | ||
| - | {{:techtalk:evo:priclutch:clutchbasket-springplaterivets-blown-jbyun.jpg?250|}}((Image by jbyun - xlforum.net/forums/showthread.php?t=49915)){{:techtalk:evo:priclutch:clutchbasket-rivetdamage-blown-vferdman.jpg?250|}}((Image by vferdman - xlforum.net/forums/showthread.php?t=49915)){{:techtalk:evo:priclutch:springplate-blown-xlxr.jpg?250|}}((Image by xlxr - xlforum.net/forums/showthread.php?t=302142)) | + | {{:techtalk:evo:priclutch:clutchbasket-springplaterivets-blown-jbyun.jpg?280|}}((Image by jbyun - xlforum.net/forums/showthread.php?t=49915)){{:techtalk:evo:priclutch:clutchbasket-rivetdamage-blown-vferdman.jpg?280|}}((Image by vferdman - xlforum.net/forums/showthread.php?t=49915)){{:techtalk:evo:priclutch:springplate-blown-xlxr.jpg?280|}}((Image by xlxr - xlforum.net/forums/showthread.php?t=302142)) |
| \\ | \\ | ||
