Clutch Woes

ok so i swapped out my clutch and though i would come back with my findings.

#1 my factory installed clutch measured out perfectly even ay 2.5mm (inside of spec wear limit WTF!!) but my springs measured out at 48.2mm
ahh i see said the blind man - not enought pressure to wear the rest of the damn thing out (spec is minimum 50mm according to the manual) - still 24,000 miles wow 1/3 of the factory clutch used at 24,000 miles holy crap! makes me wonder how far the kevlar will go.

#2 factory clutch bolts suck! 5.8ft lbs of torque my a$$
i used 5 different torque wrenches only to have each one shear a bolt head off the factory bolts, and each of the auto store replacements i tried ( i got very good at bolt recovery ) 69.6 in-lbs = 5.8 ft/lbs right ? i ended up having to replace all my clutch bolts with m6-1.0 25mm steel hex bolts and 1/4in plated washers (thank you home depot) and installing them to the thread count.

Mine seated "finger tight" at different thread turn counts (see pict) but all reached the same torque at about 17.75 - 18.25 turns from the start of the thread. at roughly 72 in/lbs i couldnt get a consistant reading below 72. thank god they held up to the pressure this time!

on first assembly i found that my new bolts touched the shifter arm in the casing by .5mm ... but after putting on the new gasket i came up with an extra 1.0mm all the way around

Fully assembled and sealed up and this thing is tighter than he77 .... i had a hard time keeping it held in for 2-3 min test (stop light test in the driveway) i let out a little slack - pulled it in and it felt good.... for the first time i was able to fully load my forks

for being the first wet clutch i have ever done this went pretty smooth - not as bad as i expected.

bought the clutch friction plates (all 8)on clearance for 19.99 + 7.50 shipping
bought the EBC high-performance springs (all 6) for 12.50 + tax
bought bolt and washer kit from auto parts store 9.99 & returned since the sheared even with their loaner tool.
bought the steel Hex bolts 2 for .98 needed 6 i bought 12 - just in case 6.50
bought the washers needed 4 for .98 6 bought 12 - 3.30
bought clutch cover gasket 18.50 turned out to be wrong part returned and made case gasget from sheet of cellulose rubber for 6.75.

I was recovering the recently changed oil lost a little oil in the process and decided to change the oil again even though it only had 550 miles on it
2.99 *4

all in all under $70

 

tidy job, i think i need to have a look at mine, it runs great but slipps like a bitch if you give it any gas in fifth, doesnt slip in any other gear??? at first i thought it was wheel spin as it ws wet but allas no, it seems to be a clutch issue

 

mie was shuddering under hard accelaration in 1st and 5th - not slipping now, but i havnt driven it more than 10 miles since the new clutch

 

nice write up

S!