[blind180]

looking for help with clutch problem- recently replaced basket, center, plates, discs and springs and cannot get enough free play in cable. It is bottomed out at the lever and the adjusting barrel ( can't make it any looser ). tryed a new cable and it is so tight that i had to go back to the older one that is slightly stretched. went back and removed and reinstalled evrything but no change.

Parts used:
oem basket, center
Barnett clutch kit with plates, discs and springs
Honda Pro 80/85 trans oil
oem cable
ASV pro lever and perch

History:
new bike in march 07
Burnt up oem plates, discs in august replaced with oem
Burnt up oem plates, discs recently, basket and center were gouged up so replaced with oem

Always make sure lever has play, he does not ride it.

Any suggestions why we can't get any freeplay in lever?

Thanks!!!!!

[blind180]

well it looks like nobody had an anwser but several are interested in the topic so here is what i learned.

Don't use the aftermarket Barnett kit!!!! We switched back to OEM after everyone questioned the aftermarket kit and presto we have tons of freeplay like you should. for the record we took the barnett kit out and reinstalled once already just in case something was not right but it made no difference.

Bottom line- use Honda clutch components, unless you want to spend the big bucks on the Hinson kit

[woodsman]

What oil are you running and how much? How much freeplay does the lever have? If it is adjusted right it should have about 1/2 an inch of wiggle room before it disengages.

[blind180]

we use honda 80/85 HP trans oil in a crf25or and the crf150r. as much oil as the manal calls for then checked by the checking method. we know you need that much play and always run that on every bike we have owned and the three we have now, that has been the problem we found....with the barnett clutch kit there was no play at all ( I have installed at least 15 clutches so feel comfortable i know how) you could not reduce the cable length at all in order to get freeplay, put the oem clutch kit back in and everything is fine. I have not measured the barnett thickness yet but will and will post results. something about that kit wether its plate or disc thickness or spring thickness it did not work, maybe the kit i got was packaged wrong? sticking with oem!!!!