Problem with new clutch

Mello-Yellow · 26-May-2005, 17:26

Fitted a new clutch to the 996bip '00 model

What has happened is after fitting it all together and running up the engine i noticed that the pressure plate seemed to be running out of line like a buckled wheel. Disengaged the clutch a couple off times and it ran normal. Started it again and it ran out. What has happened is the last friction plate has fallen out of the basket and not gone back in.

Should i leave out some off the steel plates or could it be i have been given the wrong basket/clutch kit. the number of plates matches up to what the haynes manual says.

Anyone else had this problem before.

JPM · 26-May-2005, 17:29

Is this an OEM clutch or an aftermarket jobbie? The symptoms you have sound like the clutch pack is too deep and needs reducing, but if you have swapped it for the same item then something is a miss.

Mello-Yellow · 26-May-2005, 17:42

Yeah all genuine parts fitted. Thats what makes me wonder if the basket is wrong due to the number of plates being right with the haynes book at least. think i got 9 steel plates off the top off my head will have to count them when i get in the garage tonight.

[Edited on 26-5-2005 by Mello-Yellow]

rockhopper · 26-May-2005, 18:03

The last plate shouldnt be a friction plate, it should be a plain pressure plate.

Mello-Yellow · 26-May-2005, 18:09

It is. The end/last friction one has jumped out should have put.

rockhopper · 26-May-2005, 18:19

From memory and i could be wrong you should have two plain plates then alternate friction/ plain plates ending in a plain plate. Is the pressure plate sitting down correctly? Its should be almost flush with the edge of the basket. Did you change the basket as well or just the plates?

Mello-Yellow · 26-May-2005, 18:53

Have fitted new clutch plates and a new basket
part numbers on invoice are
19810271a clutch housing
19020013a clutch disc set

have fitted as you described 2 plain steel plates then alternate friction/steel there is also a dished plain plate 1.5 mm that i have fitted dished side out as in manual.

the last friction plate is flush with the basket then there is the last plain plate aswell, so when the pressure plate releases the plate falls out. like there are to many plates got 9 plain and seven friction (just counted them)

keefer · 26-May-2005, 19:47

I would take out one of the first plain plates so you just have one then friction plain and so on.
with the whole stack inserted there should be about 4mm gap up to the edge of the basket before you put the pressure plate on.

keefer · 26-May-2005, 20:03

sorry forget that I just remembered that one of those plain plates is dished (the first one)
still sounds like you have two many plates in there though, remove a friction and plain plate further down the pack and see how it fits up

andyb · 26-May-2005, 23:13

I think you have too many plates.

I also think the 4-5 mm stack height adjustment is to do with a slipper clutch not as in this case a std clutch.

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26-May-2005, 17:29	#2
JPM Registered Forum User BSB Star Posts: 5,682 Join Date: Jun 2001 Location: NW England Mood: Soon my pet, soon Is this an OEM clutch or an aftermarket jobbie? The symptoms you have sound like the clutch pack is too deep and needs reducing, but if you have swapped it for the same item then something is a miss. Reply

26-May-2005, 18:03	#4
rockhopper Registered Forum User Ducati Corse Posts: 3,367 Join Date: Jul 2001 Location: Pinxton The last plate shouldnt be a friction plate, it should be a plain pressure plate. Reply

26-May-2005, 18:09	#5
Mello-Yellow Registered Forum User 500SD Bikes: 848 EVO & Multi 1000ds Posts: 533 Join Date: Mar 2004 Location: Wolverhampton, West Mids. Mood: When's the sun coming out It is. The end/last friction one has jumped out should have put. Reply

26-May-2005, 18:19	#6
rockhopper Registered Forum User Ducati Corse Posts: 3,367 Join Date: Jul 2001 Location: Pinxton From memory and i could be wrong you should have two plain plates then alternate friction/ plain plates ending in a plain plate. Is the pressure plate sitting down correctly? Its should be almost flush with the edge of the basket. Did you change the basket as well or just the plates? Reply

26-May-2005, 19:47	#8
keefer Registered Forum User Ducati Meccanica Posts: 2,518 Join Date: Jul 2004 Location: hants Mood: Found a CR250. Let the bone braking begin I would take out one of the first plain plates so you just have one then friction plain and so on. with the whole stack inserted there should be about 4mm gap up to the edge of the basket before you put the pressure plate on. Reply

26-May-2005, 20:03	#9
keefer Registered Forum User Ducati Meccanica Posts: 2,518 Join Date: Jul 2004 Location: hants Mood: Found a CR250. Let the bone braking begin sorry forget that I just remembered that one of those plain plates is dished (the first one) still sounds like you have two many plates in there though, remove a friction and plain plate further down the pack and see how it fits up Reply

26-May-2005, 23:13	#10
andyb Registered Forum User BSB Star Posts: 6,720 Join Date: Feb 2002 Location: northampton Mood: Has change happened...must of missed it! I think you have too many plates. I also think the 4-5 mm stack height adjustment is to do with a slipper clutch not as in this case a std clutch. Reply