'94 M900 Clutch slipping - less than 1k miles

[Real Recognize Real]

I installed a Barnett Clutch pack ~ 600 miles ago. No problems at the beginning but within the last 1-200 miles, I've noticed that I would have to let the clutch lever out more than normal when moving from at stop. Also, this only happens after riding for a while - the clutch seems to grab normally in 1st gear at the beginning of the ride. Well today, the clutch definitely slipped in the lower gears. I checked the friction plates and they seem fine. What else should I check?

[Speeddog]

When was the last time the clutch fluid was flushed and bled?

[Real Recognize Real]

When was the last time the clutch fluid was flushed and bled?

Clutch fluid bled about a month ago, but it hasn't been flushed recently AFAIK.

[sofadriver]

(Don't know if this applies to your bike)

I had this exact problem after installing a Barnett clutch in my ST4s. The problem was the slave cylinder wasn't bleeding off fully after the clutch lever was released. I could open the bleeder and fluid would spurt out and I had no freeplay at the clutch lever. Also, if I loosened the 3 screws that hold the slave, the clutch would force the semi-pumped up slave out of it's flush position. That's not supposed to happen.
A half turn clockwise on the adjusting screw/rod that pushes on the master cylinder at the clutch lever did the trick and allowed the slave to bleed off normally again.
I've tried to rationalize why a clutch change would cause this and never could  fugure it out.
But, who cares - my clutch worked fine after I did it.

[Real Recognize Real]

Update...

I bled the clutch several times, however I experienced the same problems so I decided to ziptie the clutch lever to the handlebar overnight after reading about this technique in other threads. I assume this means that there was some air in this system that I wasn't able to remove due to normal bleeding procedures. That seemed to do the trick so far and I have a properly working clutch (knock on wood). I'm not sure exactly how this fixed the problem, but I'm glad it did. I kinda forgot how much effort it takes press in the clutch.

[brad black]

(Don't know if this applies to your bike)

I had this exact problem after installing a Barnett clutch in my ST4s. The problem was the slave cylinder wasn't bleeding off fully after the clutch lever was released. I could open the bleeder and fluid would spurt out and I had no freeplay at the clutch lever. Also, if I loosened the 3 screws that hold the slave, the clutch would force the semi-pumped up slave out of it's flush position. That's not supposed to happen.
A half turn clockwise on the adjusting screw/rod that pushes on the master cylinder at the clutch lever did the trick and allowed the slave to bleed off normally again.
I've tried to rationalize why a clutch change would cause this and never could  fugure it out.
But, who cares - my clutch worked fine after I did it.

because when you removed the pressure plate and pack the spring in the slave cylinder would have forced the piston out a little and pulled more fluid into the master cylinder than before.  when you reassembled it with the new clutch that fluid couldn't get back past the seal on the piston into the reservoir and so was stuck in the pressure side of the system.

[zooom]

when you did the Barnett pack, did you do frictions and steels as a whole kit or what?

personally....I have tried 2 different Barnett clutches on 2 different bikes ( 1 was a wet clutch on a Kawi) and both gave me the same slipping result which I did not like and both times chucked the Barnett parts in the trash and replaced with new OEM and never had issue again....