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Discussion Starter · #1 ·
Hi all
I have just fitted a complete NOS clutch to my T100R.
Torqued it up as in manual, fitted plates and done up springs now for the problem.
When i pull the clutch in the outer basket now has 1/4 of an inch movement in it, it was fine when I put it on with no plates in but now there is like I say a lot of movement in the basket.
Any ideas what I have done wrong.
Cheers Alan
 

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Mzcombo,

"Check the clutch hub roller bearing diameter, the rollers
themselves and the bearing of the clutch sprocket for
excessive wear and pitting etc. Measure the rollers, clutch
hub and clutch sprocket bearing diameters and compare them
with the dimensions given in "Technical Data"

The above is right from the manual, I would be looking at
the rollers first then the surfaces that they ride on second.
That is where most of your play would have to be.

I replaced my rollers however still had too much play on
the bearing surfaces, I have a little play in my basket but
it seems to have done no harm. A quarter of an inch would
have me checking the above though.

Pookybear
 

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Discussion Starter · #3 ·
Clutch basket

Hi
Thanx for that the only thing is its all new every bit as in the tech drawing in the manual is new. it went on well fitted well.
then when I pulled the clutch lever and kicked the bike over to make sure the pressure plate rotated square I toughed the basket with the clutch pulled in and it moves up n down.
Are they meant to do this ?
Cheers Alan
 

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then when I pulled the clutch lever and kicked the bike over to make sure the pressure plate rotated square I toughed the basket with the clutch pulled in and it moves up n down.
Are they meant to do this ?
Cheers Alan
Ok Alan,

Well the best I could get was a slight wobble, under an eighth of
an inch. However it was in my rollers and would have an inregular
movement to the wobble.

As for your problem...

all new parts, as I do not know where the parts came from,
did you measure the rollers before install? Not all parts are equal.

Also ckeck the thrust washer there should be a little play when
put together, but not much.

I would take the time to measure all the new parts just to
make sure this is not the problem.

I would guess you did not kick over the bike with the old clutch
installed before you started this job. That would give you an
idea of the starting point. Finally I would say if you remove the
new clutch for some measurements, just kick the over again with
no clutch and watch the shaft. It should spin with no wobble or
up and down movement.

Pookybear
 

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Pookybear, or any other knowledgeable person--

I just installed a new primary chain on my 71 T100R and noticed something similar: With a new chain and thrust washer and everything tightened down, but no tensioner or clutch discs yet, the clutch basket has play in it. It will move maybe a strong 1/16 inch in and out (such that a thicker thrust washer would reduce the play). I installed new rollers, but the play is really in the "thrust" direction.

Is this normal?
 

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It will move maybe a strong 1/16 inch in and out (such that a thicker thrust washer would reduce the play). I installed new rollers, but the play is really in the "thrust" direction.

Is this normal?
Hey ed h,

Well a 1/16 is .0625 on an inch, and it depends on how you
got your measurement. If you are sure you are moving the
basket evenly in and out?

Now when I did my clutch I had a 1/8 of an inch wobble in the
basket, but that number was on the outer edge of the basket
so the true thrust measurement was much smaller because of
the distance involved from where the clutch rollers are located
compaired to where the outer edge of the basket is. Remember
the word wobble is the key word in the above statement.
measured on a rocking back and fourth movement that amplifies
the total effect.

And still I think I am pushing it a bit on play. I am really needing a
new basket, however waiting till I change out the primary for
that job. All about the money you know.

I really do not have a specific number for thrush to give, the
manual such as it is leaves you guessing. More of just a feel
kind of thing. Hard to say a little of play but not to much.

Maybe someone out there has a good range of numbers to
give out.

The problem with too much play is going to be excessive wear
on the primary chain, and the chance of the rollers of the chain
breaking or cracking.

If you are useing your old basket remember that it is the other
thrust surface and is worn as well.

Pookybear
 

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Pookybear--

Thanks for the reply. After I posted last night, I did a pretty exensive search on this site and a few others, and the consensus seems to be that some thrust play in the clutch basket is normal, and 1/16 inch is nothing to worry about. As you say, there is a difference between thrust play and wobble. My 1/16 was pretty much pure thrust play. My wobble was easily three times that.

It's good to point out that when the clutch is engaged, the play should go away since the pressure plate will be pushing the basket back against the thrust washer.
 

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Did the mainshaft have lateral play? It shouldn't ... make sure it's properly secured to the inner gearbox cover on the opposite end. The tab washer that keeps the nut locked sometimes loses its tab to keep it seated and the nut will work loose.
 

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Hey Ed h,

T100rc has a good point there I had both of my covers off
at the same time. It would be wise to check that one out.

Thanks T100rc for the help.

1/16 of thrust seems like a bit much. When some fancy
math is used with triangles I come up with about .025 of
thrust on my ride. And like I said before that seems like to
much to me still.

So since you have restated that you did get your number from
evenly pulling on the basket, I would look into trying to find
where the play is comming from and try to tighten it up some.

Remember that the 1/16 of an inch you are running right now
will also have to be taken up every time you pull in the clutch.

That maybe the difference between neutral or not when running.
Mine is right on the edge of that fine line, so I know it is not
quite right. Sometimes neutral is easy, sometimes I am there
a minute finding the detent. However, not a big deal for me
I only need neutral once a day.

Pookybear
 

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pookybear & t100rc--

The clutch shock body runs true and has no play, so I'm pretty sure mainshaft is OK. Out of curiosity, I put an indicator guage on the basket and pulled it in and out. Thrust play is only .025-.030 (sure feels like more than that).

Got another question for you guys about cam timing, but I'll start a new thread for it.
 
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