Clutch replacement, was not expecting this

[Spikes]

Reading through this thread as I'm having clutch trouble also but here's something to ponder - I worked in a machine / welding shop for around 12 years that had a flywheel machine. People brought me flywheels from all sorts of stuff, as I was known as the guy who would fix the things that others turned away and was very accurate with grinding them. On stepped flywheels like the one you have, the outer surface needs to be ground as much as the friction surface. A diamond wheel is needed as the Silicon Carbide particulate wheels don't keep a sharp enough edge to get the lower step level all the way in.
That's it - There's no voodoo to it, as long as the exact same amount is removed, you can take all you want off the friction surface (within reason). Those are the two dimensions that matter. I don't know much, but I know I had a lot of happy customers doing just that.

 

[jaxs]

I don't have any chapter and verse to quote on the subject but I don't understand how taking a few thousandths of a wheel could render it useless. Far more clearance is created as clutch disk wears down in normal use.

 

[North Idaho Wolfman]

I don't have any chapter and verse to quote on the subject but I don't understand how taking a few thousandths of a wheel could render it useless. Far more clearance is created as clutch disk wears down in normal use.

Just trust the people that have worked on them for years, It matters!

 

[North Idaho Wolfman]

Reading through this thread as I'm having clutch trouble also but here's something to ponder - I worked in a machine / welding shop for around 12 years that had a flywheel machine. People brought me flywheels from all sorts of stuff, as I was known as the guy who would fix the things that others turned away and was very accurate with grinding them. On stepped flywheels like the one you have, the outer surface needs to be ground as much as the friction surface. A diamond wheel is needed as the Silicon Carbide particulate wheels don't keep a sharp enough edge to get the lower step level all the way in.
That's it - There's no voodoo to it, as long as the exact same amount is removed, you can take all you want off the friction surface (within reason). Those are the two dimensions that matter. I don't know much, but I know I had a lot of happy customers doing just that.

Yes you are exactly right, just very few ever do it the right way!

 

[BastropMetal]

I think the seal looks fine, you should be able to see where the old seal rubbed on the crank sleeve, compare to that mark.

It always bugs me when a kit parts don't match.
Did you compare the the old clutch pack and clutch disks to make sure they matched?

As far as I can tell they match. I have looked over the clutch discs closely and I'm very confident they are the same shape, and size, at least to the degree I can tell by eye. I havent put calipers on every dimension. In post #43 I mentioned that the adjustment bolts dont seem to be the same, but all the other dimensions on the clutch assembly seem right to me.

 

[North Idaho Wolfman]

As far as I can tell they match. I have looked over the clutch discs closely and I'm very confident they are the same shape, and size, at least to the degree I can tell by eye. I havent put calipers on every dimension. In post #43 I mentioned that the adjustment bolts dont seem to be the same, but all the other dimensions on the clutch assembly seem right to me.

Ok, Carry on!