Lightweight Clutch tight in operation

Locust · Post by **Locust** » Tue Oct 23, 2007 9:34 pm

OK forget my first problem I think that is now better.
When I did ride the bike for the 4 miles to check the smoke, I returned home and over that mileage the clutch got to the point of not disengaging I had to stall the bike to get into nautral.
The clutch lever needed two hands to operate it (something not right)
After long talks with several members and Jampot spares, it appears my clutch (which should be a 350cc clutch) 250 CSR was not correct, I did not have the thick first plate, In time I managed to get a 250cc thick plate, then I found I could not fit all the 350 plate in (should be 9 in total)The basket would not allow it.I then settled for a 250 set up (7 plates).
Having reassembled the clutch on the bike today and set it up as per book I find that the clutch lever is miles too tight, it feels as if the cable will not last long, I have tried rerouting the cable and still no good.
Any ideas please to desperate Locust.

Don Madden · Post by **Don Madden** » Tue Oct 23, 2007 10:44 pm

Sounds like the nut holding the clutch hub has loosened. Cheers, Don.

SPRIDDLER · Post by **SPRIDDLER** » Tue Oct 23, 2007 10:46 pm

Can you see the plates actually separating?
Have you overtightened the pressure springs (wrong springs?) so that they become coil-bound before the plates separate sufficiently?
(Just a thought although IKBA about lightweights).

bag-o-nails · Post by **bag-o-nails** » Wed Oct 24, 2007 2:54 am

Hello locust
does your bike have the duplex chain?
sounds to me like you have too many plates in
there it is very easy to get it wrong
the f neil book is not very clear is it?
I have the plumstead book there should only
be four friction playes in there
cheers b-o-n

Circlip · Post by **Circlip** » Wed Oct 24, 2007 3:06 am

Doesnt matter how many plates you have in there . As you have proven to your self changing from thin to thick and reducing the pairs makes no difference.

You could be spring bound as Spriddler suggested or wrong springs, but I think its your adjustment on the cable to the cam,ie the adjustment on the big nut on the thrust plate is not matched with the cable.

On the other side of the gearbox is a small plate with 2 bolts in it ,under there is a cam, your probably coming to the end of your cam travel.

While your in there remove the push rod from the main shaft and check if its bent, grease and replace. There should also be a ball bearing riding the cam that pushes the push rod if thats missing well???Edited by - Circlip on 24 Oct 2007 02:09:07 AM

bag-o-nails · Post by **bag-o-nails** » Wed Oct 24, 2007 4:14 am

Hi Locust
the order and number of plates
Are as follows

1.thick plate shamfer towards you
2.plain steel plate
3.friction plate
4.plain steel
5.friction plate
6.plain steel
7.friction plate
8.plain steel
9.friction plate
how have you set up yours?

cheers b-o-n

Locust · Post by **Locust** » Wed Oct 24, 2007 11:34 am

DON. The clutch hub nut is tight.
SPRIDDLER. ( how did you get a name like that) Yes can see the clutch is free but too tight at lever, springs are new from Jampot spares but do look too strong.
B.O.N. Being a CSR 250 yes it should be a 350 clutch but as I said I could not get all the plates (9) in the basket.
I have the Plumstead book with the 250, Scrambler, and 350 set up.
CIRCLIP. Yes the 250 clutch set up should be OK as I not racing the bike, the wrong springs are a possibility but they are new from Jampot spares and the same as my old ones ( are there lighter ones ???) the push rod works OK without the plates in and I get full travel, balls are in and OK.
So I am not happy about the springs I did try some Triumph springs, this made the clutch lighter but they were not strong enough and slipped, someone did mention B52 gearbox springs has anyone tried them.???
I do appretiate all the help lads
Graham

Circlip · Post by **Circlip** » Wed Oct 24, 2007 12:11 pm

Sure it not the cable that is tight under load? Routing OK

paul knapp · Post by **paul knapp** » Wed Oct 24, 2007 1:22 pm

Locust, sounds to me as if you are giving the springs too much pre-load!..you say they 'do look strong'.
Try winding OUT the spring adjuster nuts by one, two or more extra turns than the 'book' specifies.

Paul

SPRIDDLER · Post by **SPRIDDLER** » Wed Oct 24, 2007 1:38 pm

Are you using the correct spring cups? Maybe they are too long and preventing full throw/release of the plates.
Very silly thought, but does the lever and cable move freely when disconnected at the clutch end?
All seems very odd!