Clutch anomally

I installed a new clutch and cable about a month ago and have noticed something interesting.
I have the clutch adjusted to optimum settings when cold. After I ride and all is warmed up good, the clutch play increases from nearly zero lash when cold to about 1/8" when warm.
Is this normal? I can't figure out what could be causing this to happen.
Any Ideas?
Thanks

 

Any ideas on this one? Thanks

 

Not normal.

Installed new springs when you did the clutch?

Does the clutch slip under load?

Are you sure everything was done correctly?

 

I replaced all metal and friction plates. Did not replace springs because they were well within specs.
The clutch does not slip either cold or hot under load.
I assembled as per the Hayes manual and exploded parts view.
I believe I did it correctly.
:?:

 

Might be the springs. When they are warmed up they might be a little weak and colapsing just a touch. If you are going back in there to check things. You may want to boil some water and put a couple of springs in there, then check them. Careful they will be hot. Be sure to dry them off befor reinstall if they are good.
Anyone else have any ideas?

 

When the cable gets warm ... it expands.
But, 1/8th Inch seems like "A stretch."

It does not matter if you have your Clutch dialed-in for Zero Lash ... because, you can easily adjust it to still be perfect with a small tweak of the adjusting Knurl at the Clutch Perch.

 

Yeah Rick, that's what got me 1/8th difference cold to hot is quite a lot.
If you take 1/8th out when hot to get zreo lash it's going to be too tight when cold.

 

Thanks for the input, good ideas!
I am going to try something:
I will mark the clutch lever (engine end) exact position when cold then look and see it's position when hot. This way I can get an idea if it is actually the clutch internals or the cable itself, will this work?
I did notice that the new clutch cable I installed is about 2 inches longer (OEM part) than the original. I checked the routing and all looks good.

 

That should work nicely. At least you wont have to dive into the clutches again without being certain this is the problem. Cable would be a lot less messy of a job. Good luck and let us know the end of the story.

 

Well,
I have put about 500 miles on the bike since I posted last and there have not been any operational problems but I am still experiencing the additional clutch play when the engine warms up.
It has really been bugging me so i decided to tear back into the clutch to see if I might have done anything wrong when I did the cluch job to begin with.
Based on the tear down, I had everything in there correctly as per the Clymer repair manual.

Samsr wrote: "Might be the springs. When they are warmed up they might be a little weak and colapsing just a touch. If you are going back in there to check things. You may want to boil some water and put a couple of springs in there, then check them."

Great suggestion, did as suggested with no measurement change.

Everything looks good, all plates, friction rings and springs are well within spec. measurements.

The only thing I can think of is this:

behind the first clutch plate there is what thee manual calls "a built-in dampner" which is held in by a circlip. They suggest not to fool with it.

Well, on the first go around I took this spring off so I could get to the first clutch plate to change it with a new one.

Behind this first clutch plate is what the manual calls a "plate". This "plate" is not completely flat, it is concave/convex in nature.
Now, I took this off the clutch boss assy. when I did the first clutch job.
When i put it back on during re-assembly, I was not sure which way "not-flat" plate was to go on so I took an educated guess.

I am wondering if I put this non-flat plate in backwards.

Does anyone know what I am refering too when I refer to this "non-flat" plate which is behind the first clutch plate closest to the engine on the clutch boss?

Do you think putting this on backwards would create the problem I am experiencing?

Thanks

 

Any ideas?

 

Based on the exploded view of the clutch assembly below, what number is the part you are referring to?

 

Part number 9

 

lol...ok well maybe someone can help you know that we know what you are dealing with and talking about. I don't remember which way that plate goes.

anyone else??

 

Sorry, a picture is worth a thousand words, should have posted the diagram.

Anyhow- anybody know which way this item number 9 on the diagram from above goes since it is not flat. :?:

 

Anyone have an answer for me on this one? :?

 

I really can't see any problem with your clutch.
My has been performing same way since I bought bike.
Every time when it is becomes little too hot (harder riding) there is some extra free play on clutch lever.
It bothered me for some time and then I realise that it's normal.
Since then my XJ has done some 85000 km.
All OK.

I have changed friction,steel plates and all springs as old one started to slip before 30000km. Same thing...

 

Thanks for all the input. I think I have to agree with you frappe,
I re-assembled the clutch, being very careful about what goes where and it is now working wonderfully. It still does have a bit more play when the engine is warm but not so much that it causes any issues.
Took her out for a ride this afternoon and all is well. :wink:
Thanks.

 

Just make shore that you have adjusted cable free play with cold engine, and rideeee!