I need some clutch help

[aaronb]

My clutch has been acting up lately, to the point where i am afraid to get too far from home.  The friction point has moved from mid way to right out to the beginning of the lever travel, and the smallest amount of pressure will disengage the clutch.  i disassembled everything today and the outer most friction plate measured out to 2.88mm (my manual states to replace at 2.80).  The plates towards the back show minimal wear and still have some of the original grind marks on them.  The problem seems worse when the engine is hot, but the clutch doesn't slip at all, i did a few little power wheelies no problem.  Everything is stock except an open cover and stainless steel springs, 07 S2R 1000, 13k miles.  Could it be the springs?  I am at a loss and hate to throw parts at it.    

thanks in advance,
Aaron

[Ddan]

Have you made any adjustments at the lever?  There is a bleed return screw that can be turned a bit to adjust lever travel but if you go too far you block off the fluid return to the reservoir.

[aaronb]

i didn't realize there were any adjustments at the lever.  i'll look into that, thanks. 

[Howie]

Have you made any adjustments at the lever?  There is a bleed return screw that can be turned a bit to adjust lever travel but if you go too far you block off the fluid return to the reservoir.

Yep, you want 1 - 1.5 mm. free play at the lever.  Also make sure the pushrod moves freely through the throwout bearing.

[aaronb]

ok, how the hell would this happen?  pressed it back in and now everything feels back to normal (i bleed everything out too)...  but i haven't taken it on a long ride yet, so i didn't get anything too hot. 

[aaronb]

meh, after a warming up, the friction point is right back at the outermost point in the travel.  i guess that 1/8" is within the range of the slave and just adjusted for it. 

i guess i'll play with the lever...

[Speeddog]

Did you bleed it, flushing through a couple reservoirs full of *fresh* fluid?

[aaronb]

yup.

[Bigbore4]

We had one doing this a couple years ago.  There are 2 holes in the bottom of the reservoir.  The one farthest from the piston was plugged.  As the fluid heated up and expanded, it could not expand into the reservoir.  Take a look and a gentle probe with a toothpick.