Hayabusa 1999 buggered clutch?

[alfiestorm]

Hi all
Got this 1999 busa which when sat idling make a right horrible knocking sound which is fuggin loud and you can feel it through the bike how ever when the clutch lever is pulled in it goes completely silent and smooth.
whipped the clutch cover off and noticed the clutch spring bolts were loose, aha me thinks and sorts the loose spring bolts, starts the bike and no difference ok then strip the clutch out of the bike completely and I find the back torque converter the dogs on the back of it are quite worn (bike has been hammered then) pulled out the basket and the springs in the back of it rattle about like a load of marbles in a can and it is quite easy to move the basket back and forth on the back plate with very gentle pressure using a screw driver in the slots at the back.

I am assuming that the basket springs combined with the back torque wotsit are the cause of the knocking clutch. the needle roller bearings on the shaft are good no play when the basket is slotted back on and the bearing spacer is in fine fettle. clutch plates both steel and fibre are good

Don't know the history of the bike apart from it is a fair bit unloved scratched body work dirt and grime all over it and the damper srews on top of the forks don't click any more and look as if a chisel has been used to turn them (nice). the damping is in full on mode and cant be adjusted. The bike has 42000 miles on it and has led a hard life .



Is there a place to get the basket re-springed etc.



Anyone else had same clutch issues with a hedge abuser


can the damper adjusters be repaired or are they fuckered completely. 


alf

[bigkenx]

Someone might know better than me but could be clutch basket / bearing strip clutch for signs of wear I'd say fella

[Hobbs]

 Yup, sounds like your clutch basket is well past it's prime. However these can be re-furbished . As the riveting is a bit specialised you might want to farm this out. Talk to Gary at Grumpy's 1260. When you re build you might want to consider fitting a spacer ( Carpenter ring ) in the back of the clutch. This effectively locks up the back torque limiter which allows quick starts without the juddering.
Also, as you probably know, the fibre and steel plates are not all the same thickness.  There are two of each that are thicker  ( 3.8 and 2.3 mm respectively ) Your manual will tell you the correct position of these in the stack. Finally, as there is no lock tab on the clutch nut make sure you get it properly tight 95 Nm or 71 Ft lb.
Happy clutching
Hobbs

[dj23bol]

I've got a similar sound on my gsxr 1100 wt but when the bikes up to operating temp the noise goes away. I've no other issues with the clutch and it works faultlessly