Or, too thick a clutch pack creating too much drag when disengaged. I find a pack thickness of under 38mm to be better and only flat steel plates (no convex plates) makes for a much better pack separation. If (with engine off) when clutch lever pulled fully in the pack will spin freely, and continue to spin a little after you let go during the spin then it is good if, however it is resistant and won't 'freewheel' at all then you'll struggle finding neutral when stopped.
From start up and gets worse as gets hot. Just done 3 miles and it got worse but before going I have flushed fluid fully
In that case, please indulge me by trying replacing the top 3 plates or so with old ones. No need to ride it to test, just do it with cover and fairing off.
Plates expanding slightly when hot, making overall thickness even thicker? Try overall pack of 36 - 37mm, if you get any slip fit some stronger springs.
Ok so took out stock spring caps and they are 1.5mm deep. The after market bike came with fitted (got originals in box) 2mm deep. So removed a little from stack height. To be exact removed 2mm and all almost perfect. When cold no issue neutral when hot bit of wiggling but I can live with that. Next test ride out to see for slip. Hmmm nice day today...
Have you looked at the DCT ‘Auto’ conversion for that model Lucas? Eliminates all future clutch issues for good.
Define wrong spring caps as bike came with them all working. Obviously previous owner adjusted for them with clutch pack. Stack height of 38.5 is correct but it did not work. Frankly I had to remove about 3mm of stack height yet caps only introduced 0.5mm difference so where is the 2.5 coming from? Unless that aftermarket clutch plate is also wrong depth a d previous owner adjusted for that as well.
All aftermarket pressure plate, clutch plates, basket, springs, spring caps and even possibly drum (although have yet to find one), can have dimensional discrepancies that may lead to clutch operation problems, and we haven’t even started on slave cylinders and clutch levers.
I more thing i found, if the fluid level is low when you remove the pressure plate the fluid level can drop below the minimum and introduce air into the system.
