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Clutch Plate Replacement

4082 Views 21 Replies 12 Participants Last post by  Bob777
My Challenger clutch slips under heavy load at times. I'd like to put the Barnett clutch kit with the extra plate and upgraded springs in.

My question is, can I do this without actually removing the clutch basket from the bike? The service manual lists a "staking nut" (#4 in diagram below from the Challenger manual) which is torqued to 125 lb-ft which must be removed to fully take the clutch basket out, and of course this requires a special procedure for locking the crankshaft.

On the TS111 it looks like a very simple job (see this post) to change the friction plates and springs without major disassembly. Looks like you can take the pressure plate off without touching this "staking nut". Is the PowerPlus the same way?

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95% of clutch issues can be traced back to improper adjustment. Its best to adjust the clutch while the engine is hot. Why, because the clutch plates will be compressed more pulling more tension.

Since the clutch Freeplay is a fairly small range. If its adjusted cold. And then the bike warms up to operating temp sometimes the free play will be taken all the way up as the clutch plates get tighter.

Also, another possible issue is that with the slipper clutch and RPM increases, the clutch plates are forced tighter, if the Freeplay isn't there, they move tighter and slip wearing out he clutch.

The first 500-1000 miles the clutch may have to be initially adjusted several times, due to cable and the clutch plates breaking in.
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