Clutch advice for an R1?

[DreamTheater]

Hey guys,

Clutch has been slipping for a while (since I bought a new ebc clutch) and I picked up a 2nd hand clutch the other day for $50 so I thought I'd swap it over to see if it fixes it.. anyway I took the clutch apart today and the friction plates looked fine and the steels a few black burn marks on them until I get to the last few plates which get horribly worse..

First we thought it may of been the spring (This clutch only has one spring plate rather than multiple springs) so I replaced it with the OEM yamaha one which made it better, but it still slipped.

When my mechanic was showing me how to pull apart my clutch he mentioned there was a bit of wire holding the last 2(?) plates in place, this bit of wire wasn't there but inspecting the clutch i found a very small piece of this wire about 1-2cm long inside the basket.
My guess is somehow the clutch has just shredded this wire if it came loose and really messed with the last few plates but before I put it back together I'd like to know if this piece of wire is really needed in my clutch or if I can put it together without it.

My bike is a 2001 Yamaha R1, running "Castrol Power 1 GPS Motorcycle Oil 10w40" oil.

Here's two pics of the last friction and steel plate compared with other normal ones..





Tried calling my mechanic but he isn't answering and may be busy and I'd really like to get the clutch back together as soon as possible so any help is much appreciated!

Cheers
Graham

[Slug_BM]

That friction plate looks like it's past the use by date. I'd be concerned about the short bit of wire. The microfiche shows a wire circlip that holds one of the first plates into to basket. Perhaps the wire is from that? Are you certain that there are no bits of metal floating around in the sump?

[DreamTheater]

I haven't checked the sump but inside the clutch basket I found two pieces of wire about 1cm long each so I think the wire's been destroyed somehow

after a few more google searches i found another forum post that says it isn't really needed.

I've put the clutch back together but the cable is too loose so I think i've done something wrong, trying to find out what it is now

[jules_1972]

Pics of the complete assembled clutch would help.

Did you measure the stack height?

[DreamTheater]

I'll take a pic of it now, just gotta take the cover off
I didn't measure the stack height, how do I check this on my '01 R1? It's just a normal clutch not a slipper clutch like the later models

[DreamTheater]

I've made sure it's all back in the same as OEM Parts Yamaha YZFR1 (YZFR1N) 2001 CLUTCH - Cheap Cycle Parts
#13 was the wrong way around but it's the right way now

I think #8 is the bit of piano wire which isn't in there at the moment too

[filbert]

Are the plates dry? That can leave a lot of play in the cable.

[DreamTheater]

both sets were soaked in oil and are wet

[DreamTheater]

I'm fairly sure the clutch is okay now but the cable is really loose and I can't use it to change gears.. adjusted the engine & lever freeplay bits and no change..

could it be a faulty cable or am i still doing something wrong?

[darkfibre]

The clutch actuator may be on the wrong teeth causing the cable slack. Does the manual show any factory marks that should line up (on the linkage) when the cover is on?

[DreamTheater]

I was thinking that could be it but I've put the cover on 100 times each time making sure it lines up with the teeth and it always seems to have the slack

on the outside it has a line and a dot (my camera wont take a photo with enough quality to show the small dot) which are lined up when the cable isn't attached to the clutch, when i attach the cable and pull on it then it moves forward normally to disengage the clutch.. I don't know if the clutch is disengaging though it doesn't feel like it is :\

EDIT:
found a pic of it in the service manual

[darkfibre]

If the cable worked before the clutch change, you are looking at something that happened during the job. Installed height is a measurement of the clutch pack stack height, it would have to be way off for this to be the problem.

You need someone who has done one to look over your shoulder.

[DreamTheater]

Got it working, wooo!

turns out what I did wrong was when I put the cover on the actuator bit was facing straight ahead (so the dots lined up as i put the cover on) but I was supposed to have it facing left so when I attach the cable the dots then line up, and after that when i pull the cable it disengages the clutch...

I feel so stupid knowing it was something so simple, but that's usually what alot of problems are

Cheers for the help!