Heavy Clutch

[willjanuk]

Hi Guys,
Riding my Z1 and pulled clutch in and it felt like the cable broke but it had'nt and still had a bite at the end of the the lever.

I tried adjusting the clutch but it was very heavy on the lever, so went through it and found that the friction plates were very difficult to remove, which i felt was odd.

I had replaced the clutch with A.P.E ones and the pusher and release gear when I first got the Z and has never been a problem.

I have even tried putting it back with all the original parts and the clutch is still heavy.

Any Idea's. ???????? Thanks Wil.

[wilsonsjw11]

Wil,
Did you grease the release mechanism at the rebuild stage?
Replaced what with APE ones the plates?
Regards
Steve

[willjanuk]

Hi Steve,
Yes greased release mechanism, and yes the plates are A.P.E with an extra presssure plate.

[wilsonsjw11]

Wil
Is the problem the same with a hot or cold engine?
Regards
Steve

[willjanuk]

Hi Steve,
Yes, the same.
I have lubed the cable, greased the release mechanism, clutch rod, and pusher.

Everything moves fine, but when I put the spring plate back on and tighten up the bolts, it becomes very hard to pull in the clutch.

I have dismantled it down to removing the plates a few times and although the clutch will work, it is not right.

I have a Z1A that I have just restored and even with the standard clutch it is quite easy to use.

[PAULJAC47]

Oil ?

[z1bman]

does the lever get harder the closer it gets to maximum lift? have you tried it without the extra plate? what springs are you using? are they binding on the pressure plate or the inner drum ?

[willjanuk]

Hi Z1bman,
When I stripped the clutch I had the A.P.E extra plate installed and found the friction plates were tight on the tangs, so I put the original plates, pusher, springs,clutch rod and release arm back.

The friction plates went back easily compared to the A.P.E ones and I don't think the A.P.E were tight when I first fitted them, ?

I have tried both sets of springs with no difference and are not binding, lever the same pressure bake to the bars.

[Crofty]

Have the thinner plates worn into the fingers on the basket and the splines on the hub, Debbens recommended me to not use the APE kits as this can happen, you would be pulling against the indentations caused, I would of only thought that could happen with a lot of hard use. Crofty

[willjanuk]

Hi Crofty,
That sounds like what could be happening, but I can't see where the plates have worn the fingers to cause the clutch be be heavy.

And as I see it the pusher only lifts the spring plate and not the friction/Pressure plates, ?

I do ride the bike quite hard but the A.P.E clutch has been in for years now and never had a problem till now.

[z1bman]

the clutch plates shouldn't affect the operation of the clutch. clutch springs or misalignment of the pressure plate & smooth operation of the push rod & clutch lifter / adjuster is vital for a smooth lever. are the stubs on the centre hub central to the holes in the pressure plate

[willjanuk]

Hi Z1bman,
It do'es seem to be something to do with the spring plate as with it off the lever to pusher is fine with a finger over the pusher it moves freely.

Everything lines up on spring plate and tightened down evenly.

[z1bman]

i did a h1 last year & you needed both hands to pull the lever it turned out to be the pressure plate had been installed of centre & not allowing the springs to compress evenly & the spring where rubbing on the mounting lugs

[willjanuk]

The spring plate slides on the inner basket mounting lugs and bolts down, I can't see how you can misalign it, ????

[Crofty]

you are right the plates won't affect it, is the pushrod free through the g/box shaft?