Dry Clutch Issues

[arai_speed]

So on a past ride this weekend I noticed that my bike (2007 Monster S4RS) was having some major issues when accelerating.  I would get on the gas, the engine would spin but the bike would not accelerate.  The bike would accelerate only when I gently got on the gas, which from what I read points to the clutch slipping.

I got home, took the thing apart and started measuring the plates and springs per troubleshooting tips found on the shop manual.  The individual clutch plates thickness measured 2.8 mm to 2.9 mm on some areas.

The entire clutch pack measured 28.1 mm to 29.00 mm depending on where I measured.

According to the shop manual the minimum thickness should not be less then 2.8 mm per plate, which none of my plates exhibited but are very close to.  I checked the springs and none of them where below the manuals 36.5mm free play lenght minimum.

I don't know much about dry clutches but based on the information provided should I go ahead an order a new clutch pack?  Is the thickness of my plates to close to the limit which could be causing the slipping?

Any feedback is appreciated.

[ducpainter]

You could order a new pack.

I think I'd try and get a hold of another steel plate and increase the pack thickness.

Those clutches will work as long as there is friction material left on them.

[arai_speed]

Thanks Ducpainter, I don't mind getting a new pack, I just don't want to do it if it's not necessary.

Where can one go about getting 1 extra steel plate?

[erkishhorde]

What I always do is order another pack when I start getting slipping. Then take a steel or two from the new pack and put them into my old pack, sticking a piece of paper into the new pack where I took out a steel. I figure since clutch packs don't go bad from sitting, getting one now and having it on hand for when I really need it won't hurt. That and the fact that I have never been able to go with the recommended stack height and always have to finesse my stack height.

But if you don't wanna do that, I don't know why but I keep all my old clutch packs so I've got extra steels if you need em.

[arai_speed]

Erik - that would be very kind of you to part with an old steel plate.  You riding with Mark anytime soon?  Or I can swing by a convinient place for you to pick it up.

PM me. 

[erkishhorde]

PM sent.