Clutch Install Problems NEED HELP ASAP!

Hi guys I changed my clutch friction plates today (9) When I installed the new springs i torqued them to 22 lbs and i get a really stiff lever, upon loosening then i get a better feel. I turn the bike on and when i shift into first it jerks really hard and stalls. Seems like the clutch is still engaged. Went to Honda and a service tech told me i might have an extra friction plate in. Any ideas?

 

How many did you find when you pulled it back apart and checked?

 

We removed nine and installed nine the same way they came out

 

It does sound like there's an extra plate in there, or the clutch plates are hanging up on the clutch basket fingers.

Everything looked kosher when you took it back apart?

 

Yes, everything looked good, when I loosen the bolts over the springs I get good movement through the basket, but when I tighten it down it engages the clutch. When loose the plates all move smoothly and don't stick

 

The first disc is different from the rest, it has a larger I.D. to allow room for the judder spring. Is the order correct?

 

Also you might want to try deburing all of the teeth in the basket and on the discs.


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Take it back apart and make sure that first friction plate is correct. Its the sequence (first friction has a different diameter.) Install the metal ones with the smooth side going in towards the engine.

Don't use a torque hammer on those springs! Get a t-handle and just torque them down that way, if you can't get your hands on something like that, use a nice 1/4 drive rachet socket combo. If you break one of those springs using a torque hammer, your gona be hating your day, trust me.

 

Check the length of the springs compared to the OEM and make sure they aren't too long and are going into coil bind when they're tightened.

 

I just did a clutch on a bike and compared the old springs to the new ones and there was barely a difference. Bear in mind, that this is the hairy eye ball way of doing it.

How is the second gear on your FJ? I remember those bikes back in the day, all of them had blown second gears and bent shift forks. Cheers...

Always like the FJ btw, handsome bike

 

Thanks for the compliment. My second gear is fine, but I've always been careful about the 1-2 shift. Speed shifts are what did the damage and I'm pretty conservative in that respect. They stand up to the
abuse pretty well, but if you keep at it they will fail, and the only recourse is to pull the gears and undercut the dogs. And replace the shifting fork if necessary. I've got about 60,000 miles on it and basically
haven't ridden it since I bought the VFR in 2000. Here's a pic from a couple years ago:


Okay, sorry for the hijack, and back to your regularly scheduled problem.