Katana clutch problem

[Smallkat]

The plugs are part number 21215-49000 and they look like this:

If you do as Blix suggests, when you turn the back wheel only the inner clutch hub should move when in gear. Although it may move a little in neutral too. That would be a good test.

[Kryten]

Ok. So after an interesting day WFH. Including seeing an electrical drawing of a power supply, from an offshore ElasticTrickery Tech, that ought to have had a “Marlboro” watermark I got into the Kat Kabin.

Don’t worry too much about item #31 Cushion. It is an anti rattle damper to reduce noise between the clutch primary drive/outer basket and the oil pump drive gear. You wont notice that noise above the rattle from the clutch basket!

As is so often the case, when all else fails RTFM

So I’ve snapped a couple of bits out of the Haynes Manual!

‘S’Easy when you read this bit quickly

Photo of the missing rubber....

[Mac13]

Cheers guys.
How many of these rubber cushions are required?

Kryten - RTFM? I got a feeling this may be my next move?

[Mac13]

About £2-£3 for that cushion. But, £6 for postage! Robbing Tw"ts!

[Smallkat]

RTFM - read the f~cking manual

Who charges £6?

[Kryten]

Took the clutch off the engine on the bench and had a play at putting it back together again. That’s fun....

What I would do to in order to make it a little less fraught is get a permanent marker and mark across the oil pump drive gear where the drive dogs are and similarly on the outer basket where the engagement slots are to aid re-assembly.

Looking at it when the drive dogs are engaged and when they are not, one thing is clear. There will be minimal clearance between the clutch outer and the inner edge of the crankcases when the dogs are out! There should be about 5mm when assembled up correctly.

There is a little arrow cast in the clutch outer that points to where one of the slots is.

When assembled you can just get your fingers in at about the 4 O’Clock point and check the oil pump gear

[Kryten]

Took a load of photos.

And did some measuring.

Spacers were 18mm washers 1.6mm springs 49.92mm.

Spacers have big chew marks from the springs

Clutch inner. Badly worn.

And heating evidence on the plain plates

[Mac13]

Kryton,
I just checked my springs and spacers!
I bought a replacement clutch kit (EBC)including springs and the springs match the one I took off.
Spring length 40mm
Spacer 12.5mm
washer 1.5 mm
Bolt length 35-36 mm (old eyes)
Is this the problem?

[Smallkat]

That clutch inner hub is your problem. It's not allowing the plain plates to release.

[Smallkat]

Also, do the hub and shaft have any alignment marks? I seem to remember building a Suzuki engine that you had to align something in the clutch, but I can't remember what!