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Discussion Starter · #1 ·
I swapped out my clutch plates but now that I have everything back together, the clutch won’t engage/disengage the gears. I’ve aligned the clutch cable arm the dot to the arrow…anyone know how to trouble shoot this? Would really appreciate it.
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Discussion Starter · #4 ·
It seems to be an issue beyond the cable and more to do with the clutch and plates itself.
The issue is, even down by the clutch arm by the gearbox (what’s pictured above), pushing it in doesn’t engage/disengage the clutch so I can change gears if that makes sense. So it’s likely something to do with the way I put the clutch back together if I had to guess?
 

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OK, it an XSR, so it has the OEM slipper clutch. When I bought my OEM kit to put the slipper clutch in my 2016 FZ-09, it came with a couple clutch plates that are thicker than the others and they are the last 2 that are installed and the final one has to rotate one notch position.
 

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There is a trick to getting the gear of the arm lined up when sliding the cover on or your lever will be stiff and unable to engage the clutch. You have to turn it further than you think and the gear will turn as you are putting the cover on. The only other problem I encountered is that the triangle piece on the basket can be put on backwards because it is unmarked.
 

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Discussion Starter · #13 ·
OK, it an XSR, so it has the OEM slipper clutch. When I bought my OEM kit to put the slipper clutch in my 2016 FZ-09, it came with a couple clutch plates that are thicker than the others and they are the last 2 that are installed and the final one has to rotate one notch position.
Yeah my kit also came with a few extras, I took a micrometer to the metal plates to make sure I was getting the plates with the right thickness. I didn’t measure the total thickness of friction and metal plates before soaking them in oil, but unless there were some issues in manufacturing it shouldn’t be an issue. I also followed the service manual and placed the plates in the correct order with the last one notched into its own slot like you mentioned
 

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Discussion Starter · #14 ·
There is a trick to getting the gear of the arm lined up when sliding the cover on or your lever will be stiff and unable to engage the clutch. You have to turn it further than you think and the gear will turn as you are putting the cover on. The only other problem I encountered is that the triangle piece on the basket can be put on backwards because it is unmarked.
I had to take the cover off and on and make small adjustments to get the arm/lever in the right place lining up the dot and the arrow. It’s a bit of a pain. Thankfully I realize I didn’t have to take the whole cover off every time and I could just keep the screws slightly screwed in and the cover will push off just enough to move the rod a notch at a time.
I’ll double check the triangle but I believe I have it on the correct way since the indentation fits the screw head and springs best one way.
 

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Discussion Starter · #15 ·
As stated some of the fibers are different and if they are stacked in the wrong way your clutch will do just as you stated . Start over
what do you mean by the fibers? I’m assuming you’re talking about the friction plate? The friction plates can be placed in either direction, I believe it was just the metal plates that had the preferred direction.
The metal plates were placed with the sharp edges pointing outward as several videos were recommending. I also stacked the plates as directed in the service manual.

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I'll 2nd the advice above. If it isn't working then go back and start over. Take it all apart and follow the instructions step by step and see if that resolves the issue. Even if you're sure you did everything right there is clearly something wrong, so you have to go back and double check.
 

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Discussion Starter · #18 ·
There is a trick to getting the gear of the arm lined up when sliding the cover on or your lever will be stiff and unable to engage the clutch. You have to turn it further than you think and the gear will turn as you are putting the cover on. The only other problem I encountered is that the triangle piece on the basket can be put on backwards because it is unmarked.
OK, it an XSR, so it has the OEM slipper clutch. When I bought my OEM kit to put the slipper clutch in my 2016 FZ-09, it came with a couple clutch plates that are thicker than the others and they are the last 2 that are installed and the final one has to rotate one notch position.
I dug through my pictures and found this, the correct placement. View attachment 173951
Just looking at the photo I’m pretty sure I have it installed backwards ;p
 

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what do you mean by the fibers? I’m assuming you’re talking about the friction plate? The friction plates can be placed in either direction, I believe it was just the metal plates that had the preferred direction.
The metal plates were placed with the sharp edges pointing outward as several videos were recommending. I also stacked the plates as directed in the service manual.

View attachment 173950
Yes #7 & 10 must be in the right spots they are different, and also #8 steel is one of a kind and must be on the very outer side. Also check if # 12 & 11 are in their proper spot and direction .
 

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Discussion Starter · #20 ·
Is there anyway to manually see if the clutch is working as intended with the clutch case off? I’m just trying to determine where the issue is and would be great to see if it’s something inside the clutch boss or if it’s the rod on the case not engaging properly with the pressure plate.

I will maybe record a video as I put everything back together so you guys can point out what I’m doing wrong…
 
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