New DP clutch plates won't fit - suggestions?

[stay_upright]

Stuff like this always happens to me - new DP clutch and the steels don't fit.

The lugs on the inside seem fractionally too wide so it *just* won't go onto the basket. I managed to push one steel on but it was tight and I can't see the clutch working with that much friction to move the steels....

So I either file each lug a little = 32 lugs/plate x 7 plates = lots of filing.

Of get GG OEM plates but that's time and potentially a lot of money (upto £10 each? = £70 not £18) and of course I'm racing on Sunday so it would be nice if I could start the bike in gear and for it not to repeatedly stall in the woods (stalled 20-30 times last race)

I checked the clutch codes and the kit is correct for a 96-2006 EC model...

I'm thinking i'll get the file out after a cuppa tea...

Anyone know if I will damage (warp) the new frictions if I use them with the old steels?

[stay_upright]

Decided to file the new plates

For my own amusement each lug needed 24 strokes of the file and with 32 lugs on each disk and 7 disks that's 5376 strokes of the file to get them to fit properly.

Now I'm off to try and get my rad panels to fit properly....

[MattR]

FYI... my bike has a DP clutch kit from the previous owner. I found the fiber plate thickness thinner than stock and the steel plates thicker than stock. The total stack thickness (all 8 fibers + 7 steels) equals the stock stack thickness. However, you do not want to mix DP and stock parts, because you will change the total stack thickness.

[stay_upright]

Does your DP clutch drag? Mine drags a bit and I cannot start the bike in gear with the clutch pulled in due to the clutch dragging. It will start in Neutral OK. Also I have to set my idle speed in neutral quite high so that in gear with the clutch pulled in it won't stall...

I tried 5w30 semi-synth this time..

It's a bit of a shame as I was hoping the new clutch would not drag.

[MattR]

It sounds like your plates are hanging up on your basket. My clutch works smoothly without drag. My only complaint is some squeal under load but this only happens occassionally. I heard this happens with the 2005+ clutches. My 2001 clutch never squealled, but it had more drag.

[gasIdaho]

FWIW, Honda 2004 CR and CRF plates work as well. They have different thicknesses though so stack height will be different, hence different configuration of plates is probable. I have Honda plates in my Rekluse and I had to play with different thickness steel plates as well as one less friction plate in the mix. No issues since. Running a 5w or 0w synth oil seems to have helped those with clutch drag issues including myself. I use the Rotella 5w-40. The Amsoil 0w-40 is probably the best but the Rotella is easier for me to get and way cheaper.