Clutch suppressor tool == POP

DougBoost said:

Thanks, but my problem is exactly that: it IS pulling the center of the clutch diaphragm towards the outside of the bike. Although in my case it's on the bench.

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It certainly sounds as if the spring has become inverted. Simply devise a way to press it back again.

DougBoost said:

I got it almost back together except for the clutch and belt drive, which had never been installed. It seemed the circlip groove was cut too low in the basket, such that there wasn't room to get the circlip fully seated, so I took it to the local shop and proved it was extremely tight but could be done.

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Did you check the clutch plate stack height? It could be that the combination of clutch plates is giving the wrong stack height?

http://atlanticgreen.com/clutchpak.htm
http://atlanticgreen.com/ndnsclutch.htm

Sure does sound like the guy gave it back to me installed and inverted, especially since as is it spins freely rather than being locked up. Only way I can think to flatten it at this point is in a vice but mine's not big enough given the diameter of the basket.

Here's a pic:

Drones76, don't you think you are a little young to be working on that bike? Go get your father and put him on the forum.

Ugh, yeah, those springs should be pointing the other way, otherwise how can they be pressing against the clutch plates? Can you put the tool on the diaphragm on the other side and pull it through? Don't get dangerous here on us. I'm sure someone has done this before.

It's not a matter of flattening it, it's a matter of getting the spring teeth on the other side of the diaphragm.
DogT

I think I'm just going to take it back to the knucklehead who did this and have him fix it. They have a big press that should make quick and safe work of this.

And L.A.B., I checked that circlip fit even with the clutch stack removed. The manufacturer should have given another 0.010" clearance between the groove and the splines in the clutch basket. I was about to give up on it and put the triplex chain setup on when the guy in the shop had the same exact unit and it measured exactly the same. The initial round of the circlip goes in ok but you really have to work to get the second time around in and fully seated.

BTW, anyone know who was the manufacturer of this belt drive setup? There are no markings or numbers on it but it appears quite well made. All I know is the previous owner bought it ~10 years ago from British Spares in New Zealand. From what I've seen on here I'm assuming it's an RGM.

Thanks again for solving this mystery that was driving me batty!

I think I would stay away from the guys that gave it back to you.

My wife loves Austin, got her PHD there at UT.

DogT

Yeah, maybe so!

I see you're in NoVa...I've spent every week of the last 3 years working the Beltway area until recently for my job. Got to know VA, MD, DC, and WV very, very well but glad to be back in Austin.

DougBoost said:

Sure does sound like the guy gave it back to me installed and inverted, especially since as is it spins freely rather than being locked up. Only way I can think to flatten it at this point is in a vice but mine's not big enough given the diameter of the basket.

The initial round of the circlip goes in ok but you really have to work to get the second time around in and fully seated.

Click to expand...

Due to the apparent excessive stack height I'd guess perhaps your guy either ran out of time or patience, and noticed that by inverting the spring it was just about possible to get the circlip into the groove. It should be obvious to any good mechanic that the clutch wouldn't work as it's assembled at the moment!

Well, we may be considered in NOVA, but it's pretty rural here. Just google maps Hume. Foot hills of the Blue Ridge. There's not a flat place on our 55 acres, unlike Austin. Hill Country, give me a break, I've seen it. The only thing that breaks the wind there is the barb wire fences with cattle hair on them.

Have to admit Austin is the only place worth anything in Tejas. Don't get me wrong.

Good luck with your project.

Dave
69S

I have locked (jammed?) the two lower nuts together to act as a depth gauge for the amount of bolt to wind into the clutch centre.

Edit - and replied to a post on page 1 without reading page 2