Replacing Clutch No1 Cylinder TDC?

badgermilk · May 12, 2012

Hey folks,

I have been getting some serious drag with the clutch on the track bike. Planning on pulling all the clutch components out of the bike tomorrow to give them a good inspection to see whats wrong.

The question is - the engine manual states that you need to set No1 cylinder to TDC. Do you really need to do this? I cant see how setting the No1 cylinder to TDC would make a difference?

badgermilk · May 13, 2012

Just took the clutch plates out without seeing to tdc no problems.

Think I might have found why it was dragging. I found 2 spring washers under the nut that holds the push rod to the pressure plate! These are not included in the diagram in the engine manual.

Anyone know if there should be spring washers under this nut or anywhere else in the clutch assembly?

Sensei · May 13, 2012

There are 2 washers on either side of the diaphragm setup & 1 Spring washer at the end of the clutchshaft rod

badgermilk · May 13, 2012

Thanks for the reply Sensei.

This is whats in the manual

Item 23 is listed as a spring washer and 19 is a normal washer is that correct?

I have 2 flat washers and 2 spring washers, so 4 in total. I was going to put it back together with 2 flat washers either side of the diaphram and 1 spring washer under the the nut. Is that correct?

Any idea why does the manual only shows 2 washers?

Sensei · May 14, 2012

Check this link out Dude , you may have this but it shows the setup alot better than yours above
http://www.af1racing.com/store/Scripts/prodList.asp?idCategory=1053

badgermilk · May 19, 2012

Thanks for that, I have put the clutch back together with 2 flat washers and 1 spring washer.

I still get a little bit of drag but is seems to be alot better. Wont know for sure until I take it on the next track day.

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Replacing Clutch No1 Cylinder TDC?

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