Problems with pressure plate install

[sportskid1]

I am working on installing my new pressure plate today and am having some issues.  After I had it installed the clutch does not seem to be working.  In closer inspection my clutch reservoir is completely dry.  It was on the low side prior to the install (actually below the low line)  but why would it drop after installing the pressure plate.  The is no external fluid leaking.  Do you think I will be fine after I bleed the clutch?  Thanks for the help.

[davejenknz]

When you removed the pressure plate, the internal spring in the slave pushed the piston all the way out and drained your reservoir. This has probably introduced air into the system.
If you push the clutch push rod back in you may see the fluid level rise again.
Take the opportunity to replace the fluid. Then do a normal bleed and you'll be sweet.

[sportskid1]

Thanks for the info.  I will just go ahead and bleed the system and hopefully all is good to go.

[sportskid1]

I bled the clutch and this did fix the mushy clutch pull but now the clutch pull is very hard and the clutch lever only moves about a half inch or so.  When looking at the pressure plate it only moves a fraction when the clutch is pulled in.  Is it possible that the slave piston if fully extended and there is no more travel to properly engage the clutch?  Should I take the slave cylinder off and push the piston back?  Thanks in advance for the help.

[ducpainter]

It sounds like you may not have indexed the pressure plate correctly.

That would put more preload on the springs and make the pull very hard.

There is a mark on the pressure plate and a corresponding mark on one of the posts the screws that hold the springs screw into.

Have you started it yet? If not I bet the thing slips like crazy.

[sportskid1]

I just double checked and the pressure plate is installed correctly but for some reason it will not fully seat against the clutch pack.  No matter how hard I try it will just sit about 1/4 inch above the friction plates which won't allow it to engage with the clutch (ie the teeth of the pressure plate are above the teeth of the clutch, not meshed together).  Any ideas?

[ducpainter]

I just double checked and the pressure plate is installed correctly but for some reason it will not fully seat against the clutch pack.  No matter how hard I try it will just sit about 1/4 inch above the friction plates which won't allow it to engage with the clutch (ie the teeth of the pressure plate are above the teeth of the clutch, not meshed together).  Any ideas?

There was a thread about some mismachined pressure plates. I don't remember the brand positively, but IIRC it was Speedymoto.

I know bobspapa here on the board got one.

You might want to pm him.

[sportskid1]

I don't know if it is a mis-machining issue as the stock plate does the same thing when I try to reinstall it.

[ducpainter]

I don't know if it is a mis-machining issue as the stock plate does the same thing when I try to reinstall it.

Then you don't have it installed properly.

The stock one worked...

correct?

[Slide Panda]

I don't know if it is a mis-machining issue as the stock plate does the same thing when I try to reinstall it.

Sounds like you might have pulled the push rod out the clutch side a bit abd now can't get it back.
To eliminate that as a problem,
1.  Unbolt your clutch slave from the engine case.
2. Seat your pressure plate.
- If the push rod was the problem, then then either plate should now seat with ease.
3. If 3 worked out, push the push rod into the throw out bearing by hand
Re fit your clutch slave.

[sportskid1]

yuu I am hoping you hit it on the head.  I did have to pull the push rod completely out as it was pretty well attached to the original pressure plate.  Without the push rod both the new and old pressure plates will fully seat but with the push rod installed neither of them will.  I will give it a try today.

[sportskid1]

Got it all figured out.  I think when I originally put on the pressure plate I did not fully seat it and when I pumped the clutch lever it pushed the slave piston to far forward so I could not fully seat the pressure plate in my later tries.  I removed the slave and backed the piston back, correctly mounted the pressure plate making sure that it was fully seated, reinstalled the slave, then bled the entire system (which had some great brown fluid come out), and went for a successful test ride.  I guess having problems is how you learn.  Now I know how to swap a pressure plate, bleed the clutch, and eventually swap the slave.  Thanks so much for your help.

[Oldfisti]

     

[Slide Panda]

I think when I originally put on the pressure plate I did not fully seat it and when I pumped the clutch lever it pushed the slave piston to far forward so I could not fully seat the pressure plate in my later tries. 

I had a feeling this was it.  Glad to help sus it out

When you removed the pressure plate, the internal spring in the slave pushed the piston all the way out and drained your reservoir. This has probably introduced air into the system.

Er.. I don't think there's any internal springs - not in the slave.  It's just a simple piston-in-bore set up that relies on the pressure plate spring for return force and pressure from the the master for extension

[ducpainter]

I had a feeling this was it.  Glad to help sus it out

Er.. I don't think there's any internal springs - not in the slave.  It's just a simple piston-in-bore set up that relies on the pressure plate spring for return force and pressure from the the master for extension

There is a spring behind the slave piston...at least the OEM units have one and I'm pretty sure they all do.

It's to keep the piston from moving back in the bore from vibration.