over 200 hp engine.how you solve the clutch problem?

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johnb
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Re: over 200 hp engine.how you solve the clutch problem?

Post by johnb »

Well I did,

starts with a friction plate, ends with a friction plate located in the grove as per manual.
7 x friction plates, 6 x steels,
same clutch which has travelled 40,000 ks
now sporting 8 friction, and no clutch slipping,
Suggest when people rebuilding there clutch, check that the puller is loose after tightening pressure plate.
Mine wasn't and and was preventing plates and steel from full spring pressure.
big difference in my case.

Cheers JB
longfiredragon
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Re: over 200 hp engine.how you solve the clutch problem?

Post by longfiredragon »

Hey, JB can you please clarify your post here, forgive me but not quite understanding. The turbo uses 8 friction plates and 7 steel plates, and yes per the manual the last friction plate is offset. ( I don't know why it's offset but going to try and find out)

Your saying you did not have all the plates in there?

And now you have 8 frictions, but only 6 steels? Or did you add another steel so you have the correct amount?

And what is the puller? The release arm?

And what is the pressure plate?

In the parts breakdown of the clutch assembly
Kawasaki lists no puller? And no pressure plate?

Hence my confusion.

Thanks.
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Lorcan
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Re: over 200 hp engine.how you solve the clutch problem?

Post by Lorcan »

johnb wrote: Wed Mar 31, 2021 12:35 pm starts with a friction plate, ends with a friction plate located in the grove as per manual.
7 x friction plates, 6 x steels,
You're looking at the wrong manual. You need to look at the turbo manual supplement, not the base manual. They are different.
First to 200mph (2006) and still the fastest (211mph)
Quickest turbo-only 8.69 @ 162mph
johnb
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Re: over 200 hp engine.how you solve the clutch problem?

Post by johnb »

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Hey guys.

Sorry for the confusion.
I've removed the clutch cover to count the plates, turns out there is 8 +1 friction plates, 9 in total, and 7 steels.
Photo shows 8, but the first friction and steel is hidden with the basket casting.
Think friction have worn so much allowing another plate to be added.
With the clutch cover removed, the puller, 46102-1061 ROD,CLUTCH, should be loose as a goose, if not then the clutch plates will not experience full spring pressure.
Mine all going in the bin now anyway, well worn.
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johnb
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Re: over 200 hp engine.how you solve the clutch problem?

Post by johnb »

Oh for the observant,
last plates (two) not located in the grove as per manual.
Sorry.
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Betterthanfabio
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Re: over 200 hp engine.how you solve the clutch problem?

Post by Betterthanfabio »

Have you measured the plates thickness?
You should try to know everything about something & something about everything.
longfiredragon
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Re: over 200 hp engine.how you solve the clutch problem?

Post by longfiredragon »

Now I got it. Lol.

I am not an expert on clutches but I have done a little research because of my recent issue and spoke to my engine builder. If you have all those steels and frictions in there, there might be a good chance there is wear on the hub and someone was trying to take up for this by adding more frictions. And even if there wasn't extra wear before there probably is now.

If that was or is the case replacing all the plates may do nothing to stop the clutch from slipping. Also it will put extra wear on the needle bearing, and washer that's in there. My first time around with my clutch I had to replace all that stuff, hub, bearing, washer, housing, everything. Let's hope not but just sharing an FYI. Also just in case, Kawasaki over here does still stock all the plates. Just got mine in yesterday. Good luck.
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Charlie @ Evergreen
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Re: over 200 hp engine.how you solve the clutch problem?

Post by Charlie @ Evergreen »

Strange D your clutch went out again. Remember when Roger built your engine it was wiped out totally and I sent him a pressure plate & inner hub for you off that 4K motor I had as yours was worn down grooved up. Wonder if that is why your turbo went out again. Betting might be??

Hope you get it working perfectly now :thumbup
84' ZX750 Turbo 85'ZX750 Turbo
longfiredragon
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Re: over 200 hp engine.how you solve the clutch problem?

Post by longfiredragon »

C, I am not sure what caused the issue. I think it was a stretched cable and therefore shortly after putting all the new stuff in when the motor was done I could never get it adjusted right. The clutch hasn't always slipped but I haven't been able to adjust the cable correctly for a while. I have replaced the cable now and the adjuster but I think it's to little to late.

All my plates measure good, and look ok. But I have read on here from several posts, and talked to Roger and been told that once they start slipping there going to continue to slip. The only fix is replacement of the plates. Pretty sure my hub, housing, and bearing and such are still good. Going to try and just replace the plates.

I have also ordered a new handle and holder/perch.

So the handle, perch, adjuster, cable, frictions, steels and gasket will all be replaced with new.

Will see what happens.
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