2003 Hayabusa 20000K miles.
Problem: Under heavy load (>6K RPM 3gear or higher) I'm getting clutch slippage. Clutch is stock
So far I have:
- Oil change Mobil 4T
- Replaced all steels and fibers and clutch plate springs, wave washer and seat washer all OEM. Each plate and fiber checked with dial calipers and placed in the exact order of the diagram. Plates soaked 24hrs prior to install. Steels installed with rounded edge towards the bike.
- Replaced slave cylinder and rod (Both OEM). greased the rod up pretty well but the seal was a little lose but I cant imagine that would be enough to cause it to do this consistently.
- Replaced all clutch fluid (Brembo) drained line completely,cleaned up the master cylinder with brake clean and compressed air/etc.
- Inspected sprocket case for cracks
- Inspected clutch cam for cracks
- Inspected inner and outer basket there were some groves (wavy type wear), I did some light sanding on the inner and outer hub to try to smooth those out a bit. I tried slipping a steel on the inner hub and holding some pressure but it didnt really bind up
- changed out 3 of the pressure plate springs with some brocks heavier springs (this seemed to help a bit) but I didnt want to go crazy and risk cracking the sprocket cover and it should work with stock springs.
I have a new inner hub coming as well as a new master cylinder (both OEM). If those dont work I'm pretty much stumped other than the outer clutch basket (they are proud of those @ $300).
What else could possibly be causing this? I'm running out of Ideas.
Problem: Under heavy load (>6K RPM 3gear or higher) I'm getting clutch slippage. Clutch is stock
So far I have:
- Oil change Mobil 4T
- Replaced all steels and fibers and clutch plate springs, wave washer and seat washer all OEM. Each plate and fiber checked with dial calipers and placed in the exact order of the diagram. Plates soaked 24hrs prior to install. Steels installed with rounded edge towards the bike.
- Replaced slave cylinder and rod (Both OEM). greased the rod up pretty well but the seal was a little lose but I cant imagine that would be enough to cause it to do this consistently.
- Replaced all clutch fluid (Brembo) drained line completely,cleaned up the master cylinder with brake clean and compressed air/etc.
- Inspected sprocket case for cracks
- Inspected clutch cam for cracks
- Inspected inner and outer basket there were some groves (wavy type wear), I did some light sanding on the inner and outer hub to try to smooth those out a bit. I tried slipping a steel on the inner hub and holding some pressure but it didnt really bind up
- changed out 3 of the pressure plate springs with some brocks heavier springs (this seemed to help a bit) but I didnt want to go crazy and risk cracking the sprocket cover and it should work with stock springs.
I have a new inner hub coming as well as a new master cylinder (both OEM). If those dont work I'm pretty much stumped other than the outer clutch basket (they are proud of those @ $300).
What else could possibly be causing this? I'm running out of Ideas.