Here is the deal:
I purchased an 08 with 3500 miles for low book last fall, and was not able to ride the bike, just load it into a trailer (there was snow on the ground in Alaska in November).
The reason for low book was the bike had been dropped on the left side, in addition to plastic damage, the clutch lever was broken. I replaced the plastic and purchased a set of Yana Shiki levers for the clutch and brake from the dealer (yes, they used the recommended part numbers by Yana Shiki). The brake lever went on smoothly, but I had to apply a little pressure to get the pivot bolt into the clutch lever (this was in December, and I have thrown away the broken OEM clutch lever). When I first rode the bike, I put about 3 miles on it and cracked the whip expecting the front to loft. The engine went right to the rev limiter. I barely made it home on the original clutches.
I replaced the clutch pack and the original one had worn fibers and blued steels (I figured the previous owner had dragged the bike and smoked the clutches, and that it was my fault for not being able to ride the bike). After replacement of the new clutches I fired it up and it SLIPPED BADLY. After much scratching of heads and talking to other mechanics I figured it was the clutch lever did not have a deep enough pocket to fully dis-engage the clutch (it was like never letting your hand disengage a properly setup lever). I drilled out the Yana Shiki rod pocket about 1.5mm, reinstalled (there was still a little resistance on the pivot bolt, but it went in a lot easier than the first time). I also bled out the slave cylinder a little for good measure. The bleeding dropped the reservoir to about half way between full and fill. I tried the bike and everything was good. Problem solved!!
Until today (about 500 miles later)....I was commuting home was at 70 indicated and flicked it to get around a car and the tach went to 6k, and the bike just slowly accelerated...The clutch is slipping again!!!
Is there something that I need to do when replacing clutches beyond what the Kawi shop manual states to keep the clutches from slipping? I guess I am asking did I do an improper installation on the clutches, or is the clutch lever still hosed?
Please Help!! These bikes are supposed to have bullet proof clutches and I am on my second set. I have not drag raced, burned out, or even wheelied the bike, so I do not think it has anything to do with my riding style at this point.
Thanx
Black Max
Black Max
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