My clutch fibers (EBC fibers, same model as prior clutch rebuild, triple checked) and plates (brand new oem 1.6, quadruple checked) dont all fit into the clutch basket. IE... My stack height is too high by almost 1 full plate. I noticed the problem after my initial reassembly. I had 0 (none) spring tension on the clutch cable lever. After at least 15 trials/checks/rechecks/rebuilds, it still would not fit. The 11th friction plate is too far out to catch the teeth in the clutch basket (the one that is indexed opposite to the other friction plates.
Understanding that my last fibers were worn, and the steels were EXTREMELY blued from heat (original ones since I've owned the bike, going on my 5 summer now) I was doing a complete rebuild. New springs (EBC) new fibers (EBC, #CK4513) and new steels (oem 1.6) I sat the old stack of fibers and steels on my table, next to the new stack of fibers and steels (11 each fibers/steels in both) and the new stack is clearly (visually, and ruler) higher by at least an 1/8 inch. They look close to even when I remove the last fiber from the new stack.....???? WTF.
Extra info. I have an A1 2000 ZX12. I made 3 trips to the dealership to check throw out bearings/rods, cables, all bolts, pressure plate, anything i could take off short of the actual hub. Everything checked out normal/to spec. I've changed my clutch at least 3 times before, and have never had this problem, albeit this is the first time I have replaced the steels.
My question is.. I removed 1 fiber and 1 steel from my new stack, (testing my theory) reassembled the whole deal, and now the last fiber sits perfectly indexed at the end of the clutch basket (10 steels/10 fibers). The pressure plate now sits normally, slightly indexed with the hub. I get the clutch cover on, adjust the cable slack per the shop manual ( I have one that has been next to me the entire time) and she "APPEARS" to be running normal (on my bike stand at least). I could not get any clutch pressure on the cable throw with a NORMAL SET UP (11 plates each). I could move the cable arm (on the cover) by hand the full throw, and it would not move any further before I had spring tension. I verified my set up at least 10 times.
It appears that the throw out rod (rod that pulls the pressure plate off of the hub/basket) is just too far away to "PUSH" the plate out. Its just holding the plates/fibers in the basket. There is about an inch of play from fully seated (in) to actually touching the inside of the pressure plate (out) when its all assembled.
The new set up (10 fibers/steels) appears to have the correct spring tension, no odd sounds, normal shifting feel, no drag in neutral, NORMAL by my checks, short of actually putting her on the road. Off the stand, I can stall the bike by slowly engaging the clutch in 1st gear. No slipping or any abnormal actions/feelings. I havent gotten out of the garage, but my bike really does appear to be normal???
Has anyone experienced this.. The basket appears to be stock, but I have no explanation of why all 11 plates dont fit. Can the bike run with only 10 fibers/steels?? What are/will be the side effects of keeping this set up. I dont want to order oem fibers, since that is at least another 2 week waiting time??? I've already been down 2 waiting for everything??
Ideas, comments, concerns.... I'm running on empty?? I'll try to post pics later, but I really dont want to take her apart again if I dont need to..
Thx
Indy12RR
Understanding that my last fibers were worn, and the steels were EXTREMELY blued from heat (original ones since I've owned the bike, going on my 5 summer now) I was doing a complete rebuild. New springs (EBC) new fibers (EBC, #CK4513) and new steels (oem 1.6) I sat the old stack of fibers and steels on my table, next to the new stack of fibers and steels (11 each fibers/steels in both) and the new stack is clearly (visually, and ruler) higher by at least an 1/8 inch. They look close to even when I remove the last fiber from the new stack.....???? WTF.
Extra info. I have an A1 2000 ZX12. I made 3 trips to the dealership to check throw out bearings/rods, cables, all bolts, pressure plate, anything i could take off short of the actual hub. Everything checked out normal/to spec. I've changed my clutch at least 3 times before, and have never had this problem, albeit this is the first time I have replaced the steels.
My question is.. I removed 1 fiber and 1 steel from my new stack, (testing my theory) reassembled the whole deal, and now the last fiber sits perfectly indexed at the end of the clutch basket (10 steels/10 fibers). The pressure plate now sits normally, slightly indexed with the hub. I get the clutch cover on, adjust the cable slack per the shop manual ( I have one that has been next to me the entire time) and she "APPEARS" to be running normal (on my bike stand at least). I could not get any clutch pressure on the cable throw with a NORMAL SET UP (11 plates each). I could move the cable arm (on the cover) by hand the full throw, and it would not move any further before I had spring tension. I verified my set up at least 10 times.
It appears that the throw out rod (rod that pulls the pressure plate off of the hub/basket) is just too far away to "PUSH" the plate out. Its just holding the plates/fibers in the basket. There is about an inch of play from fully seated (in) to actually touching the inside of the pressure plate (out) when its all assembled.
The new set up (10 fibers/steels) appears to have the correct spring tension, no odd sounds, normal shifting feel, no drag in neutral, NORMAL by my checks, short of actually putting her on the road. Off the stand, I can stall the bike by slowly engaging the clutch in 1st gear. No slipping or any abnormal actions/feelings. I havent gotten out of the garage, but my bike really does appear to be normal???
Has anyone experienced this.. The basket appears to be stock, but I have no explanation of why all 11 plates dont fit. Can the bike run with only 10 fibers/steels?? What are/will be the side effects of keeping this set up. I dont want to order oem fibers, since that is at least another 2 week waiting time??? I've already been down 2 waiting for everything??
Ideas, comments, concerns.... I'm running on empty?? I'll try to post pics later, but I really dont want to take her apart again if I dont need to..
Thx
Indy12RR