Clutch Problem Questions

[heavyd]

I had a bad noise in my clutch 2 years ago when I bought this Valkyrie and probably neglected it longer than I should have, but this spring I pulled the clutch out to replace the clutch rod bearing. The bearing was definitely bad, it was pretty crunchy when I tried to spin it. Since I had everything apart and the bike has almost 60k miles on it I took the clutch pack to a shop to get the spring and dampener plate replaced because I don't have a press. Put everything back together and the clutch was still noisier than I expected, but there was no vibration in the lever and it was much much quieter than before.

Fast forward 2k miles I started feeling a weird vibration while I was driving, kind of like a u-joint going bad except it was doing it all the time not just when I was slowing down. The clutch also started to shudder/slip pulling away, especially with a passenger but if I let the clutch out at a low speed in first and hit the throttle it doesn't slip at all. Changed the oil, thinking maybe the Lucas oil Stabilizer I put in wasn't as wet clutch safe as the bottle said. Cut the filter open like I always do and it's full of metal filings, so I gave up and had a double rum or three.

Pulled the clutch out today and built a manual press so I could take it apart myself and look things over. It doesn't smell burnt and the plates aren't discolored but everything was much drier than I expected. I saw a few little metal bits in the bottom of the clutch housing and if I rub a clutch steel between my fingers I can see metal powder on my fingers so i suspect I found the problem. The other clutches that I have worked on, the steels were uniform on both sides, but mine seem to be flattened off on one side. My current thoughts are that the shop "kindly" cleaned up the clutch pieces for me that's why they were so dry. Since it was my own used clutch, and the pack was all assembled I didn't soak the plates in oil before I put the pack back in the bike.

I also have the play in the shaft that the clutch pack goes on that I have seen mentioned in other posts. I have about 1/16th" of play, other posts say that this is normal and that the clutch normally soaks up that play?



Flattened side



Press built out of some square tubing/scrap/and an aluminum hose coupler


Is this the right orientation?




Sorry if I am rambling or skipping information, it's late and I'm exhausted. I'm going to start ordering parts tomorrow so I wanted to get this online tonight and maybe someone will have some thoughts to share.

[Hook#3287]

Can't see your pictures.

The clutch plates are to be "coated" with oil before install, soaking not needed.

Is the damper plate ok?

[heavyd]

Now that I'm not at home and signed into my photobucket I can't see them either, does photobucket not work anymore? What is everyone using instead?

The dampener plate looks fine, a few minor scuffs on it but it also has 57k miles less on it.

[Hook#3287]

I'm not a photobucket user but I understand they went all fee/subscription on everyone and are holding pictures for ransom.  Ba$tards

The mention of metal in the case is what made my think of the damper plate.  Usually the rivets go and deposit those there.

Are you sure the clutch plates and disks were assembled correctly in the clutch center by the shop?

[heavyd]

Not positive that they restacked them correctly, I stacked them according to the way I read the manual, one of the pictures showed the stack to make sure I had read it right.

I'll have to look for a new photo sharing solution tonight.

[Houdini]

Now that I'm not at home and signed into my photobucket I can't see them either, does photobucket not work anymore? What is everyone using instead?

Heavyd, Photobucket now wants $50 a month to host pics, I deleted my pics and closed my account on Photofu*kit and moved over to google photos.

[Hook#3287]

I'd bet they didn't stack them right, good you have a manual too follow.

If everything checks out according to the book, you should be good.

Outside of some damper plates crapping out  and a bad bearing once and a while, these clutches are pretty tough.

[heavyd]

I think the pictures should all be working now.

Another thing I forgot to mention, with the bike running and in neutral, as soon as the clutch is squeezed the smallest bit that is when the rattle really starts. You can feel it in the clutch slave, the oil filter, and all along the bottom of the engine. I wish I had taken video but it was all apart before I thought to take one.

[Hook#3287]

Looking at your pics, it looks like it's assembled correctly, by what I can see.  Make sure you line up the "O"'s on the damper plate and the clutch center and put her together.

You did the oil coating on the plates and discs?

My clutch made a little more noise after I did my blown damper plate 15 years ago or so, but after another 60 K, she's still working fine.

About the only way you're going to know if the rattle is gone or not is to put her back together.  If everything specs out in the clutch and you still have a vibration, it could be somewhere else.

The "Play" you mentioned is a little worrisome, but if others said it's not an issue, hopefully their right.

Hope it works out for you.

[heavyd]

Anyone know the thickness spec for the steels? The friction discs are in spec as per the manual but I couldn't find a spec for the steels.

[Hook#3287]

The plates aren't a wearable part like the discs are.  Discoloration and warpage are what you check for.

You mentioned discoloration on one side, but if not warped, I'd give them a try.

Of course your best bet is to replace all the plates and discs, but that can run into some $$$.

[heavyd]

Most of my parts arrived last week, except they ordered me in 1 clutch steel instead of 8, the rest should be here tomorrow. Seeing the new steel I realize that they are no symmetrical one side is flat, which makes me feel better about mine being really chewed up, but I'm not positive which way they stack. I don't have my manual here at work so I'm not sure if it is in it, but I'm hoping someone knows which way the flat side faces?

I don't remember the numbers off the top of my head, but when I checked the new friction plates/steel against mine, mine were on average 0.02" thinner according my my cheapo digital caliper. Not much wear, and well within spec but it does add up.

[Ricky-D]

I'm hoping someone knows which way the flat side faces?

It doesn't matter as long as they are all facing the same way.

***

[heavyd]

Thanks Ricky-D, I just confirmed that the manual does not state which way they sit....

[heavyd]

4500km of riding 2 up with luggage, total passengers+cargo in the 600-650lb range, through roads that were up to 17% grade, the clutch survived. It shook a bit at first when I was pulling away but now everything seems to have seated together fine, the real test will be the next oil filter. I am getting some weirdness in the lever, almost like the friction point keeps moving so I am going to try bleeding that again.

[Grumpy]

Friction point changing is a sure sigh the damper plate is coming apart.

[heavyd]

The dampener plate is new, less than 7000km on it.....

And it isn't all the time, it's usually if I have been riding in that gear for a while. I can run up and down through the gears with no issue but if I ride in high gear for 20 minutes then have to downshift I notice it. I've been riding my other Valkyrie so this one is still waiting for a turn at the lift table.