Topic: Clutch action really heavy, very tiny friction zone.

[Dimitri13]

The friction zone on my clutch is nearly non existent. It goes from disengaged to fully engaged in a matter of mm's. I have proper free play in the clutch lever, and proper adjustment at the actuator. I've replaced the friction plates and springs, and deglazed the steel and fiber plates. I have no idea what the little locknut and adjuster screw does, but I've turned it a bit and didn't seem to affect anything. The clutch lever also seems very heavy. I didn't use hd springs. The cable is also newish and lubed. Bike is a 550k0.

[camelman]

How're the clutch basket fingers?  If there are any wear grooves, then you'll need to file them down. It will feel like a brand new bike afterwards.

[Retro Rocket]

Sounds like a Barnett clutch, they have a heavy feel with little take up....?

[Dimitri13]

Clutch basket fingers meaning the tangs that the plates groove into? IIRC they were fine. And I'm 99.9% certain it's a stock clutch.

[TwoTired]

I'd blame incorrect setting of the actuator on the clutch housing.    Note the at rest position of that cover lever.  How much does it move before any resistance is felt?  Do the marks on case and lever align?

Which did you adjust first, cable or clutch cover lever?

Do you have stock bars, and is your cable routed using large bend radii?

It took me a while to get the feel of that cover lever adjustment.  But, it makes a big difference in lever "feel".

[Dimitri13]

There's no free play in the actuator at the clutch case. All the marks lined up. I adjusted it in the order stated in the service manual. I have clip ons, and the cable is routed with the no sharp bends. It was extremely stiff even when I had the stock bars.

[dave500]

having no idea what the little lock nut and adjuster screw does is your problem i think?,dont go by those adjuster dots,if you wind the adjust screw clockwise you get more engagement/less disengagement and visa versa,you have to find the sweet spot,,make sure the basket end float is close to spec though.

[Dimitri13]

So if I'm reading this right, turning the screw clockwise will increase the amount of friction zone, while counterclockwise will decrease the amount of friction zone?

[dave500]

umm?yes,,depending on how "grabby"your friction material is,,some material i guess  has less feel,and is more grabby as in on or of,,whereas some might have more feel and take up a lot less suddenly?some riders cant get the feel of a clutch either way?be sure the cable is free to move and not kinked some where along its length maybe?