I installed new clutch and fiber plates on my ‘23 yz450. Everything came out well and went in well, however my clutch lever is “loosey goosey” and doesn’t have any tension on it whatsoever. I tried everything from reinstalling the plates, double counting all plates, making sure I had no loose parts in the shop that I didn’t see when reassembling. From what I gather is that the pressure plate is putting pressure on the center (bronze piece) of the pushrod. When I move the clutch lever that is the piece that moves. Any help would be much appreciated, I signed up for a riding camp in a few weeks and don’t think the shop would be able to get a look at it in time. Thanks
*Edit: I know the screws and plate that pushes down the pressure plate are missing in this photo.
Is the push rod seated properly in the lever arm?
Ball bearing installed ?
aftermarket or Oem clutch ?
Pushrod is properly seated on the lever arm, pulled it apart and regressed as well. Ball bearing is installed, did not remove from pushrod and I looked inside and it’s still in there. OEM with Hinson OEM replacement.
Mic all plates and compare versus stock
fibers and steels
Judder spring in this setup ?
Yep, all were exactly the same. Not judder spring it’s the singular, ktm style spring. Not pictured is the plate and bolts that push the mushroom spring down onto the clutch.
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I’d be pulling it back apart and reseating Everything
pressure plate
push rod
etc
I am assuming you've adjusted your cable to compensate for the new, thicker plates?
I'm sure the push rod is in there correctly but make sure the pushrod is flush and not above the shaft it slides through, also put pressure on the rod with your finger and actuate your clutch lever to make sure it functions correctly.
Adjust your cable, either the cable itself or perch wheel.
This is the issue. I have the perch wheel all the way out and it is barely enough for the new clutch. I have looked over the cable and it seems like the only point of adjustment is the perch wheel. I ordered a new cable assuming that the current one is too stretched out.
Looking at the diagram, there are 2 different thickness friction plates (13-14) and also 2 thickness metal plates (11-12).
If you put in aftermarket plates, you need to ensure all of them are the correct thickness, same as OEM. One easy way to tell is to measure the total thickness of the entire clutch pack, all plates, compared to the stock one, and what the spec is in the manual. It sounds as if your total thickness of the pack with the new plates is just way too much.
Another item, this clutch is basically a copy of a KTM clutch and just like the KTM clutch it has a thin metal plate on both the inside and outside of the pack (#12). It's easy for the one on the inside to stay stuck to the oil and look like just a part of the hub, and then you end up with an extra plate in there. Double-check that.
I am the biggest idiot on the planet right now. I had double, triple, hell even quadruple checked the number of plates that were installed multiple times to make sure they were all there but I never counted the plates I took out, sure as shit I am missing one metal plate. Thin metal plate stuck to the damn pressure plate…. Like I said I feel like a moron right now but thank you for this post.
It happens man! We're all used to the way clutches were for decades with a fiber on each end. And that last thin metal one looks like part of the hub!!!
No way dude - you just saved me hours in the FUTURE ... that I am using for drinking. Right. Now.
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