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Discussion Starter #1
Ok it's time to tap into the brain trust here @ the .org. I installed a Barnett Carbon Fiber clutch today but can't get the adjustment right. This is my 2nd Barnett on this bike so I've done it before. I got the plates and disks in and in the correct order, (with green plate on outside). Anywho, when I put the clutch cover back on(while rotating the arm clockwise) it seems to go on fine but when I hook the cable up I have waaaay too much freeplay. The lever is all freeplay and I can grab just a tiny bit of clutch when I pull the lever all the way in. I adjusted it on the cable to both extremes, on both the handlebar adjustment and the adjustment on the motor. I believe the disks are in correctly(pretty hard to mess that up) and the pressure plate is on, with the 5 bolts and springs torqued down. Everything looked ok and there was nothing like this happening before( it was just starting to slip under full throttle). What am I missing here? :idunno: :idunno: :idunno:
 

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Well, youknow it has to come back apart, so start there. Make sure you got the right number of plates in there and they are the right thickness. The only ways I can think of for it to be so loose is either the clutch lifter is farther out (as if the plates are too thick or theres and extra one in there) or the lifter plated isnt seated.
 

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Discussion Starter #3 (Edited)
I did take it back apart. I took out all of the plates and discs, and left the judder seat and judder spring in there(more like a big washer though). I made sure there was 9 discs and 8 plates, all in correct order. I never have taken the basket out, just the discs and plates, so the only parts left are the lifter and the pressure plate. I also measured the new stack and it is exactly the same size as the old one, and the new stack seems to fit in there fine, looks just like the pic in the manual. The lifter is able to move in and out a certain amount if I grab it but I think it's supposed to. The only thing I can think of is I'm not getting the arm that is on the cover aligned right. But then again, it looks right, and it doesn't look like it could go on any other way. Now that I am thinking, I wonder if the lifter could possibly be on the wrong side of the pressure plate? Maybe I put the lifter in first and was supposed to put the pressure plate in first, or vice versa? Or would that even be possible? This F'n SUCKS!
 

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Lifter goes behind the lifter plate, the clutch arm should grab it and pull it away from the clutch stack. Sounds like you got it right, perhaps fiddle with the clutch arm and make sure its grabbing the lifter correctly :idunno:
 

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Discussion Starter #5
Yeah I'm sure I got the lifter in right because I remember I didn't even have to take the lifter out to change the clutch pack. I bet it's probably something with that damn arm on the cover. Only thing is, it's on and pointing the right way, but I don't think it could go on any other way. :idunno:
 

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Have you pulled the lever shaft out of the side case to see if you buggered it up? If it wasent engauged and you bolted the case on, you might have bent/broke the fingers that engage the lifter?
 

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Discussion Starter #9
OK I figured it out. The manual says that the green disc is supposed to be the last one in.....apparantly it's supposed to be the first. Son of a bitch! :rant:
 

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Intimidator said:
OK I figured it out. The manual says that the green disc is supposed to be the last one in.....apparantly it's supposed to be the first. Son of a bitch! :rant:
My manual showes it the last one in, and it goes in its own set of notches in the outer basket :idunno:
 

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Discussion Starter #11
G-Force Junkie said:
My manual showes it the last one in, and it goes in its own set of notches in the outer basket :idunno:
EXACTLY! That's what my manual says! It must be wrong because the mechanic at the stealership said the green goes in first and it worked. Now I have some clutch feel. Although I haven't filled it with oil or ridden it, I can actually grab some clutch now. :idunno:
 

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Looking at my manual again...The first clutch plate in is different than all the others so you actualy have 3 different styles in there, the first with large ID, the 7 in the middle, then the green outside. Perhaps you just had the first one misplaced? You can look at the schematic at bikebandit.com and see there is 3 parts numbers for friction discs, 3 different ones.
 

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Discussion Starter #13
G-Force Junkie said:
Looking at my manual again...The first clutch plate in is different than all the others so you actualy have 3 different styles in there, the first with large ID, the 7 in the middle, then the green outside. Perhaps you just had the first one misplaced? You can look at the schematic at bikebandit.com and see there is 3 parts numbers for friction discs, 3 different ones.
The Barnett actually only comes w/2 different discs and the plates. The manual says to put the large i.d. in first and the green in last. Well, the Barnett only has the regulars, plus the large i.d. disc, which happens to be colored GREEN! So with the Barnett the green goes in first and the last one is just a regular disc. Confused yet? :rant:
 

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Wewll, it makes sence, if you were putting the small ID ones on first, the stack was probally one plate too high, which moved the whole assembly out too much hence your lack of adjustment. The only reason the inner and outter plates are different (besides size) is they have to rub aghnist the aluminum of the basket and pressure plate. Aparrentaly barnet doesnt do this, you might find more wear on the aluminum parts.
 

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Just curious how many miles you have to be on your 2nd replacement clutch? My OEM clutch feels great after 12k miles of abuse, drag launches, burnouts, trackdays, clutch wheelies..........
 

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Discussion Starter #16
CBRGuy said:
Just curious how many miles you have to be on your 2nd replacement clutch? My OEM clutch feels great after 12k miles of abuse, drag launches, burnouts, trackdays, clutch wheelies..........
What the hell are you clutching your 954 for! :bonk: No no no no no! Mine came up in third when it was stock with no clutch! But seriously I'm surprised yours has lasted that long. My stock clutch lasted 15k without much abuse. The 2nd was a Barnett Carbon Fiber clutch that only lasted 6k. Although this clutch did have lots more drag racing on it, I think the reason it didn't last long was because you have to give Barnetts more freeplay than the stockers. Wish I knew that before! With the next clutch I'll do a stock one with Barnett springs, I hear that will last much longer. Have you drag raced at the track? My best ET just as the clutch began slipping was 10.58 with Jardine 1/2 system, Hass eliminator, PCIIIUSB, flapper mod, my 255lb fat ass, and strap on the front.
 
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