Hitchcocks Forum

Sorry to harp on about this clutch of mine but having sorted the cover flex I still wasn't happy with the clearance. Whilst it was hugely improved it wasn't as good as my other bikes and I could see no reason why not. The truth though is that I'd never actually pulled the clutch apart so I did today. Much as I expected it was rather a poorly constructed affair, roughly stamped plates poorly finished. I'm not sure if it had already been messed with but under the 9/16" centre retaining nut was a massive split lock washer more suited to a truck than a bike. Anyway the back plate of the centre was very wobbly with at least .020" runout. I machined off as much as I dared about .015" at a guess and emery papered all the driven plates on the lathe so that they were all polished and consistently smooth. I removed all the witness marks on the basket and the centre with a fine file and reassembled with a home made bend over tab washer http://www.flickr.com/photos/77012441@N08/7111935467/ and a fill up with ATF and Bob is my uncle! total clearance hot and cold and neutral is a light toed click from fist instead of a kick with my heel.
Happiness!

Nice work, Simon. I wonder how much of the improvement came from machining the backplate, and how much from fettling the plates. Not having a lathe (yet!) I can't do much about the backplate, but I may well have a go with the 'engaging' surfaces. A bit of attention with a fine file and emery can't hurt. Having said that, I'm thinking about the 5-plate conversion for my 625, and doubtless the plates in that will be no better finished than the existing ones, and will probably need the same treatment!
Current priority, though, is finishing reassembly after repairs following a stripped oil pump, of which, more anon.