Katana clutch problem

[Kryten]

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

The photo of the clutch inner is of my bike. The whole clutch is petty much on it’s last legs with wear.

I think Mac13’s issues are different.

We could do with seeing photos and some measurements.

[Smallkat]

Sorry Kryten. Too much wine and Amaretto.

[Mac13]

Hi,
The inner hub is new. I put the bike on the centre stand, bike in gear and spin the back wheel. Only the inner hub will spin.
I do not know anything about alignment marks? Where would I get this information? Workshop manual?
Also, Kryton mentioned about clutch springs and spacer, mine are smaller.
I am thinking that after I bought the bike the clutch was stuck, hence new cable. Maybe someone has been in and reassembled incorrectly?
Cheers

[Mac13]

Hi SmallKat,
RTFM - Done this before even posted this thread and then Blix gave me a CD copy of manuls. Cannot see anything about alignment marks? Easy to start doubting yourself and think I have done something wrong(maybe I have?). But then I was at a loss and needed to ask for help.
As for the cushion, I checked Suzuki and Fowlers. Wanted to charge about £3 plus about £6 for postage. Fowlers selling same on eBay for £6+ but free postage. Parts price are ok, it's just the postage that is charged. Would be better to buy multiple items, but nothing needed.
Thanks for your patience fellas.

[GSF34058]

I have read this whole thread three times, and a lot of Mac13's previous posts, but one thing I have not found is what engine is this problem on. Is it a 1,000 or 1,100? Please excuse me if I am missing something regarding the engine type, but my previous post was referring to my 1,000, which is the only Katana I have worked on; apart from my long gone 650G. For all I know the clutch assemblies may be the same across the whole range.

I found the old clutch springs that I replaced when the clutch on my bike was slipping. Photo shows the longest at 38.5mm. Others are shorter, so they are all bit tired. The WSM shows the service limit at 38.5mm.

Kryten, it looks to me as if your springs are 39.9mm long and not 49.9mm as you said, unless I am reading your vernier incorrectly?

David

[GSF34058]

Three more photos of the WSM that may help with the clutch reassembly, assuming this is a 1,000 or 1,100.

David

[Mac13]

Hi David,
Thanks for taking the time to help me.
My bike is a GSX1000SZ.
I have fitted the sleeve hud the correct way. With the spring washer facing inwards.
I was looking at the clutch spring not giving full movement?
The clutch process seems so simple and yet I cannot fix it. Would have been easier if something was obviously worn, broken, or missing!
Cheers

[Kryten]

Kryten, it looks to me as if your springs are 39.9mm long and not 49.9mm as you said, unless I am reading your vernier incorrectly?

David

You are correct. 39.9mm. Finger trouble on the keyboard while multi tasking!

1000 and 1100SZ clutches are the same.

[Kryten]

Hi David,
Thanks for taking the time to help me.
My bike is a GSX1000SZ.
I have fitted the sleeve hud the correct way. With the spring washer facing inwards.
I was looking at the clutch spring not giving full movement?
The clutch process seems so simple and yet I cannot fix it. Would have been easier if something was obviously worn, broken, or missing!
Cheers

Might be time to lay out all the bits you have on a bench old on one side new on the other and compare each item old vs new. Just to confirm that you have the equivalent for each. Have a cuppa while you are staring at them as well
You could alway re-assemble with the original bits to see if the fault persists.

But, please take lots of photos and post them up on here!

Another question: What oil are you using? I’ve not experienced this as I’ve only used mineral oil, but several folk on here have had issues when using semi or fully synthetic oil.

The RTFM comment was a much for me as anyone else. I stripped the clutch out of my 1000 and found (as my photos show) that it’s knackered, worn inner and outer baskets fried friction plates and distorted plain plates. The damper springs in the back of the clutch are so worn that it probably sounded like two skeletons shagging in a skip Also I found a couple of plates out of sequence, so it had been re-assembled incorrectly. I then went and re-read both my Haynes and Suzuki versions to see where I was going wrong. Both make it sound simple. But juggling the outer basket to engage both the oil pump drive dogs and the primary drive from the crank, and then fit the bearing and spacer is not that easy.

[Mac13]

Hi Kryton.
Can you get a Haynes for GSX1000? I tried in the past without any success.
The oil I put in is 10W 40 semi-synthetic.
I just now have stripped the clutch and will do as you say about comparison soon. The only this that no matter what I have tried the problem remains the same. That is unless there are two problems ie sort one, the other still there.
Buddy, I have been dreaming about Katana clutches. The system is so simple, but what would cause this problem????
Just wait tomorrow I will stare at the twats until they reveal their secret. I may be sitting for some time!
Thank you ALL for your help.