Clutch shudder on 5th gen

I have a 2001 model with a clutch shudder when cold for the first few minutes.
Has anyone else had this problem?
After the engine is warm, problem goes away. There is no slip or unusual lever travel length or take up position.
The first few uses can also be very sudden and with not much slip.
I only use the bike once a week for a 3 or 4 hour ride.
Once the bike has been used that day, all is fine even if left to go cold.
Any help would be much appreciated.

 

Sounds like sticking plates, but could be a few things. I'd check the following in this order.
1. When was the clutch fluid last changed ?, should be every 2 years !
2. Remove clutch slave cylinder & remove clutch pussh rod from the engine case. Be sure to clamp the slave cylinder when removed to stop it popping the piston out.
3. Check clutch plates & spring dimensions. You can do this without draining the engine oil.

Get a right engine case gasket before you start, put bike on side stand & remove the right side casing, be aware of the dowels & the starter gear that will come away with the cover & may then fall out.

 

I replaced fluid not long ago, I also removed the push rod and polished it and lubricated it at the same time.
Dismantling the clutch was my next move, not sure if I need any special tools for this.

 

No special tools required. 1 x 8mm socket to remove the bolts holding the clutch cover. Check the clutch operation with the cover removed & see if anything sticks.
To hold the clutch to undo the 5 clutch bolts, just pop in gear & lean on the rear brake to stop it rotating if the in gear is not enough. Then check the free length on the springs, & remove the plates lay them out in order to allow re assembly. Check thicknesses & lube with clean oil for reassembly. Check clutch basket & pressure plate for wear or damage.

 

OK, finally got to dismantle the clutch for inspection.
All parts are within tolerance, in fact will propably do another 40000K's.
Rerplaced the springs with EBC +10% just in case as they were very cheap.
Honda workshop manual shows a friction spring and friction plate between first clutch plate and disk.
I don't have them!
It also shows disk A as being of larger internal diameter. Don't have one of those either.
I might have had clutch replacement in the past.
Anybody come across this before?

 

I talked to a Honda mechanic at Hawkesbury Honda & he advised me the 2001 model didn't come with a friction spring, it might be the case only here in Australia.
He also told me they are susceptible to clutch shudder when plates get old or glazed.
Saying that, after I moved the friction plates around and fitted the new springs, problem has gone away.
I ordered new plates anyway as they are not too expensive from Ebay.
The staff at Hawksebury Honda have been very helpfull numerous times now, and I would strongly recomend them.
I have a couple of friends that take their Hondas there for work and have nothing but praise for them.

 

I have a clutch that shudders, grabs and buzzes when it engages at RPM's any higher than 4000 or 5000 RPM.

Is this what you are describing? When it happens to me, the rpms drop instantly and takeoff is totally non-linear and haphazard, almost like a machine-induced clutch dump.

So, you recommend changing clutch master cylinder fluid as part of the solution?

 

Yes, the higher the revs you use to try and escape the problem, the harder the clutch grabs.
Mine was also very noisy when this happens.
Aparently, if the clutch material gets old or overheated/burnt out it can cause this.
They told me to also look at the metal plates to see if they are bluish or discoloured as this is another sign.
You can buy new springs for around $10, and a clutch inspection only took me around 1 hour to do.
I reversed the order of the plates and reinstalled and problem has gone away.
I also ordered a new clutch as they are not very expensive, specially in the US.

 

I will buy tyres and service parts I need in a hurry and are in stock, or at least a few days away, I will also get work done there that I can't do myself.
But parts here are very expensive and are not stocked, so they have to get them from Japan or interstate, and that really annoys me.
Clutch plates here are $140.00, clutch cover gasket is $34.00 and springs $42.00, and none are in stock.
The same items from the US cost me $95.00 all up with postage, and were here in 2 weeks.
I buy oil filters and oil there, ($22.00 and $69.00 for 4L)
RK Gold chain and sprockets here were $350.00, I got them from the US for $220.00 with postage.
I would like to support local bussiness, but that much difference is ridiculous. Specially when you consider that you sometimes have to wait up to 3 weeks for parts.
Keep in mind also that until a couple of months ago, AU$1.00 was buying US$1.05 (now its down to US$0.95).
I need a left side switch block for my 2001 (blinker switch is gone), they are $142.00 here but at least in stock in Melbourne, so will take 3 days to get them to Sydney.
I will probably order it from them when I get over the cost.

 

Installing 100 pound Barnett clutch springs fixed this problem for me.