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Discussion Starter · #1 ·
got a 79 4 spd thats killing me. Ten spring clutch basket, good rollers. Put new red friction plates, (USA made) into clutch. The friction plates stacked together are 3/16 " thicker than worn pack. Way too much height on the stack to allow the pushrod to fully engage . Springs are on the money height wise according to manual. Pushrod is proper length too(no wear). If I leave one set of plates out, the clutch doesn't hold. Aftermarket aluminum Took the kicker side apart and everything looks good except a little wear on the retainer plate and starter crank gear. I also hyperextended my knee when the kicker slipped. Somebody help me
 

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You're not adjusting something right.

Loosen the cable all the way. Loosen the throwout adjustment lock nut and turn the throw out adjustment screw all the way out. Now set your springs according to the manual and try to make sure to keep them even, wherever you choose to set them. Use a ruler or calipers to verify they are set so the pressure plate is parallel to the clutch plates. Now turn the throw out adjustment screw in until you feel contact give it another 1/4 turn and lock the throw out adjustment nut. Now adjust your cable to take most of the slack out of it.

You want a bit of free play in the lever to preserve throwout bearing life.

If it slips, give each stud another half turn on the spring retainer plate

You may have to add a clutch tamer if it wants to JUMP on release.

sorry for the edit, been at the track all day, high on nitro and burnt rubber
 

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Discussion Starter · #4 ·
Ya thats about the procedure I've been working with and I've reread my manual numerous times. With the new clutch pack it's almost impossible to even get the nuts started on the threaded studs. Yes I'm using verniers to make sure that the pressure plate is parrallel. The throw out screw goes so far into the clutch pack that I can hardly lock down the nut. I'm at a loss
 

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how thick are the fiber plates ? how many fibers and how many steels ? got any part numbers ?
 

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Sounds like you have the earlier plates. They are thicker than later ones. Measure your old ones, then measure the new ones. They should be close.
 

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So, if this was a working clutch pack before you replaced the clutches, what was it doing to make you replace the clutches? With the plates totaling 3/16ths thicker, then you can figure that the hub studs will end up being that much shorter, and "almost impossible" to get the nuts started. As stated above, the earlier clutches are thicker, and it appears that, that is your problem. So a new set of clutches are in your future, if you want to ride anytime soon.
 

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Discussion Starter · #9 · (Edited)
the reason I replaced the fibre plates was they were becoming soft/mushy and causing the clutch to stick. But yes you are right about almost impossible to get the nuts on.
 

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Discussion Starter · #11 ·
Ya thats what I did, gettting tired of reinstalling the whole mess but I put the old ones back on again just to try and get it running again. The riding season is getting short, We'll see..
 
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