Need some clutch help!

[woodsm84]

I replaced my clutch plates and springs. First time ever with the help of some service diagrams. Now I barely have any throw on my clutch lever. Feels locked up. I’m assuming I have to remove the case to readjust, but I’m not sure where to do the adjustment. Any advice is greatly appreciated.

[cushman eagle]

Hello, woodsm84.
Did you replace, flush,and bleed your clutch fluid. ?
If you did and the fluid went through the master cylinder,line, and the bleeder ok,I am going to guess that one of the discs got indexed wrong and you cannot compress the pack properly.
There is no adjustment on the clutch as it adjusts hydraulically as you use it.
Please let us know what you find out

[woodsm84]

I’m thinking it has to be the indexing like you said. I did a full bleed/flush. Looks like I’ll be redoing this one

[cushman eagle]

Please let us know what you find

[woodsm84]

Definitely will. I’m going to reorder plates and springs. I’m not sure if I need to adjust anything at the basket. Basically, last time, I drained the motor, pulled the basket cover, replaced and oiled new disks and springs, then put it all together. Then nothing on the lever throw. Not sure which rookie mistake, but I’m sure it’s there.

[GrandpaDenny]

Sounds like you didn't index the first plate (last one you put in) - it doesn't go in the same slots as the rest. There is nothing to adjust.

[cushman eagle]

GrandpaDenny,I would agree with you

[woodsm84]

Sounds like you didn't index the first plate (last one you put in) - it doesn't go in the same slots as the rest. There is nothing to adjust.

Here’s a photo of it as I was putting it back together. Not sure if you can identify anything?

[GrandpaDenny]

ok the indexing looks good near as I can tell. It all looks good. When you say "hardly any throw", what exactly do you mean? Does the clutch disengage almost immediately when pulling the lever, or does it engage almost immediately when releasing, or does the friction zone seem tighter than before?

[woodsm84]

ok the indexing looks good near as I can tell. It all looks good. When you say "hardly any throw", what exactly do you mean? Does the clutch disengage almost immediately when pulling the lever, or does it engage almost immediately when releasing, or does the friction zone seem tighter than before?

It moves about 1/4 inch and stops dead at that point. When I was bleeding the clutch afterwards, my master cylinder was shooting brake fluid in the air if I squeezed too quickly. As soon as I close the bleeder line at the slave cylinder, I have no throw. Have I over torqued the pressure plate springs maybe?

[Van Voyager]

When I was bleeding the clutch afterwards, my master cylinder was shooting brake fluid in the air if I squeezed too quickly.

That's normal, and a good sign - it means the master cylinder equalizing port is not plugged.

[cushman eagle]

woodsm84,I was wondering what you have accomplished on your clutch?
We have not heard from you for a couple days.

[woodsm84]

woodsm84,I was wondering what you have accomplished on your clutch?
We have not heard from you for a couple days.

Fixed!!!!!!! One disc, one plate too many. Never trust parts from eBay. I did everything correctly, unfortunately the parts vendor did not. Thanks so much for everyone’s help

[cushman eagle]

Thank you for the good news,woodsm84
It is always good to hear of a successful,easy fix

[HMB Don]

I think you have some clutch plates that are wrong. Measure the thickness of your old plates, then Measure your new plates. Now you'll find that the old metal plates might be thinner. Now Measure the old clutch pack vs the new clutch pack. You want the new clutch pack to be just a little thicker then the old.

Why are you changing your clutch. Is the clutch slipping when you try to accelerate in the higher gears? If so you might have broken spyder springs, which are at the back of the clutch basket.

[woodsm84]

I think you have some clutch plates that are wrong. Measure the thickness of your old plates, then Measure your new plates. Now you'll find that the old metal plates might be thinner. Now Measure the old clutch pack vs the new clutch pack. You want the new clutch pack to be just a little thicker then the old.

Why are you changing your clutch. Is the clutch slipping when you try to accelerate in the higher gears? If so you might have broken spyder springs, which are at the back of the clutch basket.

It turned out to be exactly what you said about the plates! Thanks!