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Discussion Starter #1
The clutch is slipping on my (now 90,000 miles old) Blade. I damaged it coming back from Czech Republic when the reg/rec went and I had to keep the engine above 5,000 rpm to stop it dying-unsuccessflly due to very heavy traffic. So I have new plates, springs etc all soaked and ready to go in.

The old plates all slid out easy enough, bar the last one (the narrow width one) which won't budge. It is loose though as it can be moved from side to side but cannot get it to move back and forth. I don't have the tools to remove the centre nut, the circlip that holds the centre nut on, or to hold the clutch still. The last clutch I stripped was on a TZ racer, and these never, ever caused a problem.

I also think the clutch has been put on wrong before, as the parts manual I have shows that the spring seat and judder spring have been put in in front of the final friction plate, and not behind it.

Any ideas? I riding it to France on Thursday! Or maybe not.........
 

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The old plates all slid out easy enough, bar the last one (the narrow width one) which won't budge. It is loose though as it can be moved from side to side but cannot get it to move back and forth.
Are sure it's not just sticking from oil suction?
The spring seat and judder spring came out okay?
 

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Discussion Starter #3
Are sure it's not just sticking from oil suction?
Possibly, but can't get anything behind the lugs to pull it out. Cant' even get anything to stick to the plate to pull it out (due to the oil). tried leaning the bike right over and tapping the basket with a rubber mallet. No luck

The spring seat and judder spring came out okay?
They did indeen, but they were in front of the final steel plate, and not behind the final friction plate, as per the service manual.

Still stuck (pardon the pun) getting it out. Maybe why the spring seat and judder spring were in the wrong place?
 

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Possibly, but can't get anything behind the lugs to pull it out. Cant' even get anything to stick to the plate to pull it out (due to the oil). tried leaning the bike right over and tapping the basket with a rubber mallet. No luck

They did indeen, but they were in front of the final steel plate, and not behind the final friction plate, as per the service manual.

Still stuck (pardon the pun) getting it out. Maybe why the spring seat and judder spring were in the wrong place?
I can't imagine what is holding it then.
I can only suggest removing the hub.
If the engine is still in the bike you should be able to put it in gear and lock it with the rear brake.
 

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Discussion Starter #5
I can't imagine what is holding it then.
I can only suggest removing the hub.
If the engine is still in the bike you should be able to put it in gear and lock it with the rear brake.
It has an odd looking circlip stopping the outer nut from coming undone-not sure how it is removed (manual jus says "service tool required" to remove it.

This is a real headache! Not much time as doing a track day on Tuesday on my RSV (travelling up tomorrow, and back on Wednesday morning)-off to France on thursday afternoon.
 

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It has an odd looking circlip stopping the outer nut from coming undone-not sure how it is removed (manual jus says "service tool required" to remove it.
No mention of a circlip in my manual.
The nut is simply staked to the shaft.
Any chance of a photo?
It's definately a '96 engine?
 

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Discussion Starter #7
No mention of a circlip in my manual.
The nut is simply staked to the shaft.
Any chance of a photo?
It's definately a '96 engine?
Looked again at the manual, and it says "Unstake" the circlip on the nut. What does that mean-never come across any clip like that before. I'm either stupid or tired today (probably both!)

Deffo an RRS motor-doubt there is a need for a photo see as I'm instruucted to unstake the clip (or what ever it is).

Thanks-your comments ae whittling down my problem!
 

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Looked again at the manual, and it says "Unstake" the circlip on the nut. What does that mean-never come across any clip like that before.
It's not a clip at all.
The end of the nut has a soft edge and the shaft has a groove in it.
You stake the soft edge of the nut into the groove with a punch or screwdriver blade so it can't come undone.
Unstaking it is a simple matter of punching the staked section out of the groove.
 

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Discussion Starter #9
Thanks-I'll sort that in the morning (hope the neighbours can cope with my swearing at 07.00!).
 
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