Clutch '08 SDR

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Sarasota_Steve
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Clutch '08 SDR

Postby Sarasota_Steve » Mon Oct 23, 2017 9:58 pm

Hello,

Two weeks ago, Riding with my buddies, my clutch started slipping. Actually, it was the fourth thing to go wrong on that ride. I left the house before sunrise and I noticed my license plate bulb was out. No big deal, these things happen. During the ride, my right side mirror went limp (I understand it happens after 40). Then there was a little bit of moisture inside my instrument panel and later the frigging clutch. It was interesting that all my buds made the same comment. - How many miles? - 12500 - That's strange since you don't abuse the clutch. -

I took care of the 3 minor issues as I ordered a clutch kit for the LC8. (Apparently same parts for SD and SDR)

SD 2007 - UK

60032010000 steel disk
60032011000 LINING DISK 2,8MM 0
60032111000 LINING DISK OUTSIDE 2,8MM 03 £17.40 Y
60032012000 LINING DISK TURN OUT 2,8MM 03 £20.90 Y
60032034000 BELLEVILLE SPRING 2003 £18.25 Y
60032035000 THRUST WASHER 2003 £5.00 Y

60032011010 CLUTCH KIT LC8 03-13 £203.80 Y

SD 2008 - USA

60032010000 STEEL DISC 2MM 03 10
60032011000 LINING DISK 2,8MM 03 9
60032111000 LINING DISK OUTSIDE 2,8MM 03 1
60032012000 LINING DISK TURN OUT 2,8MM 03 1
60032034000 BELLEVILLE SPRING 2003 1
60032035000 THRUST WASHER 2003


SDR 08 - UK

60032010000 STEEL DISC 2MM 03 £4.60 Y
60032011000 LINING DISK 2,8MM 03 £9.82 Y
60032111000 LINING DISK OUTSIDE 2,8MM 03 £17.40 Y
60032012000 LINING DISK TURN OUT 2,8MM 03 £20.90 Y
60032034000 BELLEVILLE SPRING 2003 £18.25 Y
60032035000 THRUST WASHER 2003 £5.00 Y

60032011010 CLUTCH KIT LC8 03-13 £203.80


SDR '08 - USA

60032010000 STEEL DISC 2MM 03 10
60032011000 LINING DISK 2,8MM 03 9
60032111000 LINING DISK OUTSIDE 2,8MM 03 1
60032012000 LINING DISK TURN OUT 2,8MM 03 1
60032034000 BELLEVILLE SPRING 2003 1
60032035000 THRUST WASHER 2003 1

I went to my buddy Mark to install it today and it was easy enough. Pretty straight forward. The interesting thing is now the clutch seems its not releasing. I buttoned it up, turned the engine on, clutch in (Harder pull than before) release the clutch and nothing. No movement.

Counted the fiber and metal plates I had discarded and the count is the same. Removed plates and re-installed and still nothing. There is quite a bit of play between the last fiber and the pressure cap. And when I clutch it, the pressure cap moves but the fiber and metals do not.

Oh SD.net gurus. What did I do wrong?
Ride Hard,
------------------
Sarasota_Steve
08 990 SDR

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bic_bicknell
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Re: Clutch '08 SDR

Postby bic_bicknell » Tue Oct 24, 2017 6:52 am

Whilst changing clutch plates did you remove the clutch slave cylinder and the pushrod?

If so you may have omitted the small ball bearing that goes in the slave cylinder after the rod. This would result in the problems you are having.
Past: Honda CB125J, Honda TL125, 1963 Triumph Tiger 90, Yamaha RD250, Kawasaki KH250, Kawasaki 400 S3, Kawasaki KH400, Kawasaki Z400J, Suzuki GS750, Suzuki GS1000, Ducati SS900 Superlight, KTM LC4 Supermoto, Honda VFR 800i, KTM Superduke '07.

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No. 47
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Re: Clutch '08 SDR

Postby No. 47 » Tue Oct 24, 2017 7:05 am

Assuming that you have fitted the right number of plates in the right order and everything else on the clutch side correctly, there should not be any play between pressure plate and clutch plate pack so my immediate thought is that either the pressure plate is worn, which I doubt as you had at least some clutch action previously, that the clutch rod is not correctly seated in the pressure plate, or, assuming that you removed the clutch slave and clutch rod, that you have reassembled the clutch slave incorrectly and the clutch rod is holding the pressure plate away from the clutch pack, eg is the clutch rod locking pin correctly seated in the slot in the clutch slave mounting bracket?

If the pin is not in the right position, though, and is jammed in the mounting bracket, it would effectively lock the clutch rod and it would take a lot of force to bend the pin and allow the rod to move a little, so again unlikely but possible and may explain hard clutch action.
'08 ex-Battle race KTM Superduke 990 R No.47
'08 OE KTM Superduke 990 R
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Re: Clutch '08 SDR

Postby No. 47 » Tue Oct 24, 2017 7:11 am

PS - did you pull the clutch lever with the clutch disassembled?
'08 ex-Battle race KTM Superduke 990 R No.47
'08 OE KTM Superduke 990 R
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Re: Clutch '08 SDR

Postby Sarasota_Steve » Tue Oct 24, 2017 3:43 pm

bic_bicknell wrote:Whilst changing clutch plates did you remove the clutch slave cylinder and the pushrod?


I did not. I did notice the pushrod coming out on its own and I was able to push it back by hand. But it would immediately come back out. My guess is that I need to release mineral oil pressure from the slave side?
Ride Hard,
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08 990 SDR

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Re: Clutch '08 SDR

Postby Sarasota_Steve » Tue Oct 24, 2017 3:49 pm

No. 47 wrote: that the clutch rod is not correctly seated in the pressure plate

I'm guessing this is the cause. And like I stated on my reply to Bic, I guess I need to relieve mineral oil pressure to be able to seat the rod and stop if from moving back out, on its own.

No. 47 wrote:or, assuming that you removed the clutch slave and clutch rod, that you have reassembled the clutch slave incorrectly and the clutch rod is holding the pressure plate away from the clutch pack, eg
I did not remove the clutch slave. But may have to.

No. 47 wrote:is the clutch rod locking pin correctly seated in the slot in the clutch slave mounting bracket?
I'm not sure I know what you're talking about.

No. 47 wrote:If the pin is not in the right position, though, and is jammed in the mounting bracket, it would effectively lock the clutch rod and it would take a lot of force to bend the pin and allow the rod to move a little, so again unlikely but possible and may explain hard clutch action.
Ride Hard,
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08 990 SDR

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Aphex
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Re: Clutch '08 SDR

Postby Aphex » Tue Oct 24, 2017 6:52 pm

Did you remove and reinstall the spring and washer that sits in the back of clutch pack?

"The interesting thing is now the clutch seems its not releasing. I buttoned it up, turned the engine on, clutch in (Harder pull than before) release the clutch and nothing. No movement."

Now are you saying that the clutch is not engaging when you release the lever? Or it is not disengaging and allowing the bike to move freely while in gear?
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Re: Clutch '08 SDR

Postby No. 47 » Tue Oct 24, 2017 6:58 pm

Hydraulic back pressure possible if the reservoir is overfull but unlikely, I would have thought - try refitting pressure plate, with reservoir cap and any excess fluid removed, and push rod properly seated in pressure plate - my guess is that the top hat end of push rod is bearing on rear face of pressure plate, and therefore holding pressure plate off of clutch pack, and not sitting square in the hole in the pressure plate.
'08 ex-Battle race KTM Superduke 990 R No.47
'08 OE KTM Superduke 990 R
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Re: Clutch '08 SDR

Postby Sarasota_Steve » Tue Oct 24, 2017 10:41 pm

No. 47 wrote:Hydraulic back pressure possible if the reservoir is overfull but unlikely, I would have thought - try refitting pressure plate, with reservoir cap and any excess fluid removed, and push rod properly seated in pressure plate - my guess is that the top hat end of push rod is bearing on rear face of pressure plate, and therefore holding pressure plate off of clutch pack, and not sitting square in the hole in the pressure plate.


Gonna give that a try
Ride Hard,
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08 990 SDR

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Re: Clutch '08 SDR

Postby Sarasota_Steve » Tue Oct 24, 2017 10:45 pm

Aphex wrote:Did you remove and reinstall the spring and washer that sits in the back of clutch pack?

Actually the clutch kit I purchased came with new spring n washer.

Sarasota_Steve wrote:"The interesting thing is now the clutch seems its not releasing. I buttoned it up, turned the engine on, clutch in (Harder pull than before) release the clutch and nothing. No movement."


Now are you saying that the clutch is not engaging when you release the lever? Or it is not disengaging and allowing the bike to move freely while in gear?


Not disengaging and allowing the bike to move freely as if the lever were all the way to the handgrip.
Ride Hard,
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Re: Clutch '08 SDR

Postby No. 47 » Wed Oct 25, 2017 6:18 am

Ah! I read your OP as clutch not engaging, eg freeplay between top clutch plate and pressure plate = pressure plate not clamping clutch plates together........not disengaging would not allow the bike to move freely in gear with the clutch lever pulled.
'08 ex-Battle race KTM Superduke 990 R No.47
'08 OE KTM Superduke 990 R
'01 Ducati 996S

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Re: Clutch '08 SDR

Postby SD05 » Wed Oct 25, 2017 12:42 pm

If memory serves me well;

The clutch push rod at the slave cylinder end has a small rod/pin running through it at 90 degrees, this is a locating pin which needs to be mated up with a receiving groove at the slave cylinder end. If you pushed the rod back in from the clutch basket end, you may not have got the locating pin mated correctly.

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Re: Clutch '08 SDR

Postby Sarasota_Steve » Wed Oct 25, 2017 1:05 pm

Great info. I’ll try that!
Ride Hard,
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08 990 SDR

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Re: Clutch '08 SDR

Postby Sarasota_Steve » Fri Oct 27, 2017 3:10 pm

Done!!!. Apparently the arrows in the clutch basket and the pressure cap need to line up. Who would’ve thunk it. ;)
It truly is a 20 minute job.
Ride Hard,
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Re: Clutch '08 SDR

Postby Aphex » Fri Oct 27, 2017 6:00 pm

Hell yeah, glad it was a simple fix.

Now sign your waiver and go for a ride :lol:
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Me so Hoony.

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Re: Clutch '08 SDR

Postby Sarasota_Steve » Fri Oct 27, 2017 6:30 pm

Aphex wrote:Hell yeah, glad it was a simple fix.

Now sign your waiver and go for a ride :lol:


:) Lol
Ride Hard,
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08 990 SDR

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Re: Clutch '08 SDR

Postby Sarasota_Steve » Sat Nov 18, 2017 12:02 am

I've not been riding the SDR because I had something in the back of my mind nagging me that I had assembled the clutch incorrectly.

I took it apart tonight and I was right. I inserted the outermost fiber plate in the middle of the pack. During reassembly, I noticed that all of the tabs of the middle plates were painted green. And there was a red tab in the middle of the pack. When I took it apart tonight, I saw the red painted tab fiber plate is the outermost.
I was not able to find much info or how to's since it's such an easy, straight forward job. The only video I found is this Italian guy and he moves the last plate one notch to the right as to not align all the indentations. I don't speak Italian so I don't know what his logic is.

https://www.youtube.com/watch?v=NyqlIBNsc40&t=406s
Sorry but I could not embed the youtube video. (See 5:15)

Does this look ok to you or would you move the last fiber plate one notch to the left?

Image
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Re: Clutch '08 SDR

Postby lc4 » Sat Nov 18, 2017 2:40 am

Going by manual what you have in photo is correct.
Note that within the fibre disks there should be 2 different disks both have a different material designed to run on aluminium, the larger of the two being the first you fit.

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Re: Clutch '08 SDR

Postby Sarasota_Steve » Sat Nov 18, 2017 2:42 am

Yes, The material of the first and last disks is black instead of brown/copper color
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Re: Clutch '08 SDR

Postby No. 47 » Sat Nov 18, 2017 8:53 am

Aye, first and last friction disks are different from the rest - first one has larger id to allow for spacer and spring rings and last one should be rotated in position by one notch - some debate whether standard plates should be installed with notches in tangs aligned or randomly installed to ‘balance’ clutch pack.

Did you soak friction plates in engine oil for 24 hours min. before installing..........?
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Re: Clutch '08 SDR

Postby bic_bicknell » Sat Nov 18, 2017 10:04 am

Moving the last plate back a notch is what the manual says and what I've always did with a standard clutch. No idea what the logic of this is!

When I swapped over to a Suter slipper clutch it uses the same plates and I can't remember whether I did this in that clutch.
Past: Honda CB125J, Honda TL125, 1963 Triumph Tiger 90, Yamaha RD250, Kawasaki KH250, Kawasaki 400 S3, Kawasaki KH400, Kawasaki Z400J, Suzuki GS750, Suzuki GS1000, Ducati SS900 Superlight, KTM LC4 Supermoto, Honda VFR 800i, KTM Superduke '07.

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Re: Clutch '08 SDR

Postby Sarasota_Steve » Sat Nov 18, 2017 12:28 pm

No. 47 wrote:
Did you soak friction plates in engine oil for 24 hours min. before installing..........?


If by 24 hs you mean 30 minutes then the answer is ‘yes’.
Ride Hard,
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