Z1OwnersClub GB

Need some help please guys.
On my Z9, I have fitted a new clutch pushrod, new APE extra plate and spring kit and a roller clutch pusher. All is good untill like today, after a half hour ride, with a lot of clutch work, pulling away from a standstill and the clutch grabs, chatters rattles and then engages with a bang. Apart from that it works fine. Any ideas?

Never heard of an EXTRA plate

I'd make sure that the pressure plate isn't getting pushed beyond the end of the inner hubs splines and also that the roller pushers outer washer hasn't dropped off its locating spigot.

check the length of the push rod to make sure its not longer or shorter

maybe check one or more clutch plate hasnt snapped.not the steel ones.

That all makes sense and I'll check it all again. The problem is the same as it was before I put all the new stuff on and only when it gets hot. you can hear the chatter and feel it at the bars. If I try to make a quick getaway it's quite a big clunk as it engages. Then it's fine untill the next take off from standstill.

I had a simular problem yonks ago after an engine rebuild on my Z1B and new EBC clutch plates fitted, except it was a gguurriiing noise at take off only rather then a clunk. After many late nites and fitting a pusher kit to try and fix prob. running out of ideas, I put an old set clutch plates in and problemo fixed, those plates still in bike after 7500 miles, told the local bike shop what I THOUGHT of EBC and he got me a new set free.

Just an idea if all else fails.

RGH, very interesting...What was wrong with the EBC clutch plates?
Were they too thick?
Were they sticking on the inner alloy tooth surface or the outer cage?
Were they replaced with another set of EBC friction plates?
Are the new set good?

A bit of other info...
I have noticed that most old friction plates are mostly within specs!
I have also noticed that a new push-rod is very tight in push rod holes.
I have also noticed that when I clean the plates and rub some friction modified (GTX II) oil on the plates I always get clutch slip until I pull apart, clean and re-lubricate with the usual (GTX) oil.

For SteveH...
I have seen those radial springs worn thru the outer retaining plate and some springs broken causing a rattle. Also, I often wonder if the outside hardened plate of those roller bearing clutch release, don't come adrift, as there ain't much holding them in place.
RegardZ

The outside plate/washer from the roller bearing pusher can't actually fall away as it is held in place by the towers that the springs sit in. I have just noticed that the spring holding/outer plate has notches worn in it where it has been binding on the clutch casing. This would explain the chatter as the clutch is dragged away from traffic lights etc. The problem is only there when the bike is hot, but I wouldn't have thought that there would have been enough expansion of the metal to make this happen. Why would the clutch be coming out too far anyway?

The extra clutch plate will make the pressure plate sit slightly further out and maybe that is enough to cause the clearance issue.
The result is like spacing the clutch out.
The clutch still has to travel the same amout to disengage.
I would check how much clearance you have by sticking some plasticene on the pressure plate and see how much it gets squashed when the cover is re-fitted.
The only other cause could be that the whole clutch assembly is sliding on the input shaft due to a loose center nut.

I too fitted the roller bearing pusher and ebc clutch plates with stronger springs a few weeks ago , then last Sunday when it was hot mine also started clattering from stand still have not used it since

I'll try the plasticene trick. The clutch was doing exactly the same before I changed the rod, plates and pusher, so the extra friction plate hasn't made a difference, the outside plate still bolts firmly up. 1st thought was to simply grind off the raised seam inside the clutch casing! Back in the shed today!

Check hub splines, and cable / cam / rod return.