DragBikeMike
Serious Thumper
   
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SuzukiSavage.com Rocks!
Posts: 4471
Honolulu
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How about thinning down the plates? There are thirteen plates. If you remove .010” from each plate you would reduce the stack height by .130”. That might fit, but it would be a lot of precise work. Do you happen to have a surface grinder with a magnetic table? That would work on the steel plates, but the fibers are a different story. If the stock clutch has .157” travel, and you add a pair of plates (.115” + .062” = .177”) you reduce the travel to minus .020”. It’s an interference fit. Break out the sanders and grinders and lappers and whatnot, and lob .130” off the stack, and you could possibly restore travel to .110”. That would give you a .040” margin over the release mechanism travel. It would also reduce the spring installed height by around .047”, which would increase the spring preload. I don’t think the additional spring preload would be a showstopper, but ya gotta keep that release cam in mind.
What about the oil slots in the friction material? The friction material is right at .015” thick. You could take .005” off each side. That would make the oil slots shallower. I think those are there to provide a path for the oil to be squeezed out when the clutch is engaged. Would shallower slots cause problems with friction?
You can see from this photo that the material is very thin. The total thickness is .115”. The metal portion is .085”. That leaves .030” total friction material, or .015” on each side. Are you willing to sacrifice 33% of your available friction material?
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