Guys,

I thought I was done installing new clutch plates and for the most part I am. However... After putting everything back together, my clutch lever now has way too much slack and actually, when I pull it, the plates no longer move. All the parts are back in the clutch assembly but I'm thinking that the slop is that actuator assembly that connects the cable to the clutch. Not sure what this is actually called but are these easy to break/tweak? I'm hoping that I can just unbolt it and replace/adjust but would appreciate any advice from folks who've touched this assembly before.

Thanks,

Jae

Also, can anyone tell me if a stock MC21 wet clutch is supposed to have

- 7 fiber clutch plates
- 6 metal clutch plates

That's correct.

You'd better re-check your assembly. Did you put the ball back in the push rod?

Are all the plates properly located?

The actuator can only go in one way and cannot be adjusted.

Yup, the ball is still in and the rotating cap is on top of the ball. All the plates have been soaked in oil prior to install (wet clutch) and after bolting the pressure plate back on, the clutch lever doesn't seem to disengage the system... The actuator looks to be working fine when I pull the clutch cable by hand with none of the plates installed. Weird.

- What's the first thing installed after the judder plates? steel or friction plate?

Thanks Matt.

Jae

In fact, kinda sounds like the same situation as this post:

http://www.nsr250.net/forums/viewtopic.php?t=4854&highlight=changing+clutch

Friction plate first and friction plate last.

Progress: Checked everything over again and reinstalled the cover.

- 7 friction plates (1st and last plates as well)
- 6 steel plates
- ball and cap in place inside basket

The clutche lever/cable action now feels like normal with no gap
However, when I pull in the lever while in gear, the tranny does not
disengage. I tried again after refilling the fluid and still the same. Do
I need to run the bike after new plates to set them in place properly to start disengaging?

Just a thought here but after being a little more calm and calculating instead of frustrated, I realize what this may be:

- clutch plates just sticking?

I mean, I did notice the clutch wouldn't disengage after the bike sat for about a month. And I failed to mention that I did reuse the steel plates instead of buying new ones. Should I attempt to scrub the steel plates with a brillo?