Clutch Replacement

[He Man]

FWIW, the biggest performance improvement I have felt in the seat of my pants was an aluminimum basket and barnet clutch pack. I have done a TON of performance mods to my M1100 and for some reason the lighter clutch combo made the biggest difference...

Scott

2009 Monster 1100S Modz - Mid-Pipe Flapper removed and holes welded, Velocity stacks and K&N pods, DP Cams Degreed to Spec, Lightened Flywheel, Aluminum Clutch Basket, Aluminum Barnet clutch pack, Rexxer, PCV and Dual Autotune, HMF Slip-Ons, Shorai Battery, Lots of Carbon Fiber, Corse Colors, Re-Sprung Front Ohlins, Speedy Moto Upper Triple, Woodcraft Clip-Ons, CRG Arrows mirrors, Pazzo Levers, Electraeon Fast Throttle 1/4 turn throttle cam, Billet "Pee Cups", Frame and Wheel Sliders, Custom DP Seat, Custom Tail Chop

I can tell you that the biggest mod you should do isnt on that list.

hint: CF Wheels.

If you are going to do aluminum basket (ive had TERRIBLE experience with barnett packs, they just slip like crazy) the barnet basket is really nice. Aluminum with steel tang inserts.

[brad black]

I think you have some sort of hydraulic issue.  I don't replace packs unless they're slipping, and baskets only if they're really worn or noisy.

[Needle99]

OK...
Digital Vernier Calipers arrived today...
Stack height (squeezing stack together) is 39.01mm
Given pack is relatively worn, surprised by that..
My brother is going to dress the plates (Thanks Scoober)
Will be interesting to measure after they are dressed with the rough burrs removed.

We will definitely bleed and check things out when we re-assemble to double check...

All very new to me...So I am listening to what everyone is suggesting and will try some things.
May try the quiet clutch mod after it is all back together and working (do not want to add too many changes at once)

[SpikeC]

(do not want to add too many changes at once)

Very wise!

[brad black]

most new packs are 38.5mm I thought.  I'd assume 39 to be fine, unless it has had more plates added for some reason.

[Needle99]

Well - put clutch all back together today after the plates were tidied up...

Found the convex plate was in the middle of the stack when it was previously put back together...

Will be interesting to see the difference once the bike is ridden.

Then I can work out what of the "issue" is just me being relatively new to riding again, and my first dry clutch....

[monsterman996wfo]

Well - put clutch all back together today after the plates were tidied up...

Found the convex plate was in the middle of the stack when it was previously put back together...

Will be interesting to see the difference once the bike is ridden.

Then I can work out what of the "issue" is just me being relatively new to riding again, and my first dry clutch....

Your basket is toast. You're just going to ruin new plates without a new basket. New plates will be all banged up by 2k miles.

[Needle99]

Thanks..
Will soon be swapping out basket and plates...

After cleaning up plates noise gas subsided a little.
Had no slippage on the ride last weekend either...

So progress. .