ReMan
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| posted on 26/5/11 at 08:07 PM |
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I think you need to have a look at the clutch itself
I suspect something is stopping the plates coming apart cleanly
Hence it dragging ang breaking cables as you overpress it to compensate
www.plusnine.co.uk
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mistergrumpy
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| posted on 26/5/11 at 08:13 PM |
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Yes. I think I'll have too. What a pain but I suspect the plates are sticking somewhat, just intermittently.
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mad-butcher
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| posted on 26/5/11 at 08:18 PM |
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I know it's a different motor but on my early Blade motor there are 3 different length clutch springs
N to S 45.5mm
T and V 50.2mm
W and X 48.8mm
but if you ask a dealer for heavy duty clutch springs no-one ever asks what model and the common one you get is 50.2mm which from bitter experience
locks the clutch solid.
If you had no problems before go back to original setup and out of curiosity measure the lengths it should only be the thickness of the material used
that is different. problem must be in the clutch itself.
Tony
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mistergrumpy
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| posted on 26/5/11 at 08:29 PM |
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Ah that's interesting because off the top of my head, I'm pretty sure that the springs are different lengths. The newer, uprated ones
being longer.
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welderman
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| posted on 26/5/11 at 09:01 PM |
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I you want another pair of eyes to look over your car I can come over.
Thank's, Joe 
I don't stalk people
http://www.locostbuilders.co.uk/forum/23/viewthread.php?tid=172301
Back on with the Fisher Fury R1
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mistergrumpy
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| posted on 26/5/11 at 09:03 PM |
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Cheers Joe. Much appreciated.
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mad-butcher
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| posted on 27/5/11 at 08:07 AM |
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I'll lay money on it that it's the springs becoming coil bound before they have chance to disengage the clutch and as you're
pressing against something that isn't going to give any more something else is going to give, keep us informed please.
tony
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mistergrumpy
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| posted on 27/5/11 at 06:40 PM |
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Well I've had a look and there seems to be one or two things but not sure what the principle cause is.
The uprated clutch springs are the same length but notably harder to compress but I can only find 3 of the originals for some reason 
Here's a picture of the clutch rod. The notch in the clutch arm ^^ locates beneath the top hat as said and pulls it, which in turn releases the
clutch plates.
Now when I looked today I noticed a small burr on the shoulder outlined in red. This must have happened when I originally started this thread as I
seem to recall stripping it not long before that run. Anyway it prompted me to look at pictures of replacements to see if I could simply de burr it
and I discovered that the end should be square and not have the shoulder that mine has.
A further look compared against the clutch arm has shown that the notch isn't quite wide enough on most of my spares. This would be my fault as
instead of buying new ones because I knackered so many I just welded and shaped the notch and I haven't quite got it all an equal width. They
need filing more.
I'm wondering if maybe the uprated springs have perhaps added a little more stress onto the clutch rod and caused it to wear prematurely.
So I'm really excited now as I may have finally solved this clutch problem that I've had since building it and typically I can't
order the replacement part until Tuesday now and I'm on nights next week. Typical! 
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mad-butcher
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| posted on 27/5/11 at 07:22 PM |
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Been trying to find an exploded view of a zx9 clutch to try and get an idea how it works, came across this article,
http://www.fixya.com/motorcycles/t2629497-kawasaki_ninja_zx9r_clutch_problem
tony
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mistergrumpy
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| posted on 27/5/11 at 08:55 PM |
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Yep. Oddly enough that's the post I found and noticed the square section end that set me off looking more.
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mad-butcher
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| posted on 28/5/11 at 08:02 AM |
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Looks like your clutch works the same way as the Blade, are all the plates in correctly the blade has an odd one that goes on first and a shake proof
washer, is the bearing in the clutch basket cover in good nick ( the cover that the 6 or 7 springs hold on )
Tony
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mistergrumpy
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| posted on 5/6/11 at 11:33 AM |
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Well. just a quick update. After a week of nights I finally refitted the clutch rod that was worn and put the original springs back on and have just
managed to nip out around the block after it started raining last night
The clutch feels solid now, more so than before. I held the clutch in a few times which usually resulted in a graunching noise and nothing.
I've got it in my head now that it was the uprated springs that were causing the issue. I replaced them before I'd fitted the engine or
started it and in hindsight should have only done so if the clutch was slipping I think so cheers all for the advice, much appreciated.
Chuffed to bits  
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Richard Quinn
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| posted on 5/6/11 at 11:42 AM |
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misterhappy? Nice one!
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mad-butcher
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| posted on 5/6/11 at 11:53 AM |
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Made up for you, love richards comment about Misterhappy Now get out there and enjoy it
Tony
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mistergrumpy
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| posted on 5/6/11 at 06:31 PM |
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Have to admit that I was bobbing myself at the thought of having to push it back again but this time with the rain due. Just felt a lot more engaged.
Just have to wait for the weather now
Thanks again all.
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