Clutch replacement Problems :(

[rider4life]

I've replaced the friction plates followed the instructions on the video in the workshop section. I put it back together and there was nothing on the clutch lever just went straight in......So i took the clutch apart again...Where you put the 3 diaphram springs in theres a part that sits on top with a washer inside....I noticed there isnt that much teeth showing on the end of the crank shaft and the castle nut doesnt go on all the way like before.....I've taken it apart 3 times to makesure its all correct......still cant figure it out...what have i done wrong .

[yamahaha]

fuck me i so have that same problem just replaced the clutch and when i figure it out i will let you know

[RickOliver]

The `cup` which sits in the middle of the springs has a spline on the inside which must engage with the one on the end of the gearshaft. If it doesn`t then the cup just sits against the end of the shaft and gives the result that you`ve both described...

Rick

[mattUKNC]

The `cup` which sits in the middle of the springs has a spline on the inside which must engage with the one on the end of the gearshaft. If it doesn`t then the cup just sits against the end of the shaft and gives the result that you`ve both described...
Rick

[rider4life]

thanks rick....Just gotta get it on the splines properly and when you tighten the clutch nut it pulls it all in. Clutch is perfect now.

[yamahaha]

i have stripped the clutch for the third time and still no cigar.................. i have put it back exactly as detailed in the manual and the top hat under the nut engages onto the splines (if it doesen't it will only go on a couple of threads)counted re counted and measured clutch plates also compared the two stacks of plates and still the same problem.
when tightening up the nut diaphram springs deformed and went flat i assume this is normal as it is loading up the plates ....staked the nut .............still the same problem............i then put the clutch cover back on and adjusted the cable to such an extreme that there was no free play at the lever and the locknut on the lower end of the cable was just loose as there were no threads left to attach it took the bike out and it rides spot on no noises or clutch slip . the only thing i can think of now is that there was a ball bearing behind the clutch rod end piece that pushes off the the thrust bearing and it has dropped out when at rest there is about a 5 mm gap between the circlip and the thrust bearing housing i'm thinking of putting a 5 mm bearing between the push rod and pusher ...........help

[CMSMJ1]

the little gubbins in the casing that pushes the rod is easily cocked up.

[yamahaha]

sussed it took it to bits again and five of the brand new friction plates were bent . i really didn't expect to find that with a brand new set ................. but there you go victory at last