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Clutch Plate or Clutch Cable replacement.

507 views 15 replies 3 participants last post by  DannoXYZ  
#1 ·
Hello, I've tried looking on the forms for this question, but haven't found it.

Note: I have a 2023 Ninja 400 ABS.

I've been having a problem where I'm unable to get the clutch to bite and engage properly.

I am aware that the OEM spec is 2-3mm. The problem is when I set the clutch slack (at the top) to 3mm (using calipers), the clutch fully engages in 1st gear, without any throttle. Decreasing this makes the problem worse, (somehow there is slack, but the clutch does not fully engage before that time).

I am unaware of how to solve this. This seems beyond adjusting the top and bottom adjust. I can get the bottom adjusted such that there is no slack at all, back it up so there is slack, then fine adjust at the top.

I did recently add Norton clutch springs which I thought would help this issue, but it seems that it did not.

When riding in 3rd-5th gear, there doesn't seem to be any slippage, but this hopefully is because the Norton springs are doing their job, and there is some other issue afoot.

It seems wrong to have to add so much slack just to ensure that the clutch engages properly. If anyone has any tips/things for me to check out to narrow down the problem, I'd be very thankful.
 
#2 ·
The only thing wrong is worn out clutch plates. Everything else is fine:
  • clutch cable
  • clutch cable adjustment
  • clutch springs

Remove clutch and measure total clutch stack to verify. Picture from Ducati, your measured number will be different. Compare to standard in manual.

Image
 
#3 ·
The only thing wrong is worn out clutch plates. Everything else is fine:
  • clutch cable
  • clutch cable adjustment
  • clutch springs

Remove clutch and measure total clutch stack to verify. Picture from Ducati, your measured number will be different. Compare to standard in manual.

View attachment 36533
I assume this number is the proper thickness with all the plates? And that mine will be less than this as the plates have been worn out?

So I'd just need to replace the clutch plates inside the housing? I was worried I was going to need to do a full replacement (slippers and everything, with looked like 800 dollars), but just the plates off of PartZilla?

I read on here than many people have their plates last for a long time (I'm near 10k miles). Is this just because I ride a bit heavier and do a lot of engine breaking?
 
#4 · (Edited)
Yeah, add up all individual thicknesses in manual for total thickness.

Weak springs is cause and start of downward spiral. Once plates wear out, there’s
nothing you can do. At least you’ve got upgraded springs now to prevent next set of plates from wearing quickly. Should still measure and confirm 1st just iin case there may be some other problem. Most likely just fibre plates need replacement. Steel plates are most likely OK.
 
#5 ·
Yeah, add up all individual thicknesses in manual for total thickness.

Weak springs is cause and start of downward spirals. Once plates wear out, there’s
nithing you can do. At keast you’ve got upgraded springs now to prevent next set of plates from wearing quickly. Should still measure and confirm 1st just iin case there may vbe some other problem. Most likely just fibre plates need replacement. Steel plates are most likely OK.
Are you aware of what else could be causing this problem?
 
#6 ·
Notched fingers on clutch basket may be possibility.

Image


Also clutch cables must be oiled regularly as part of maintenance.
 
#7 ·
First step, like with electrical problems, is to measure and come up with numbers in order to find exact cause of problems. You haven't measured enough and don't have enough numbers. Somewhere, some place is number that doesn't match what manual says it should be.. aHAH!!!
 
#9 ·
100%. Luckily I have a picture and my basket looks nothing like that, all the fingers are smooth. Before I swap any parts, Ill measure the width of the clutch plates and see if it matches spec. If not.. not quite sure to be honest. Actuation between the cable and clutch seems smooth, so I don't know if it needs lubrication. There is an immediate pull with any force.
 
#16 ·
Yeah, basically furthest forward movement of lever against perch. So you've got 2-3mm of travel between when lever stops by itself to where you can push it to hard stop? This would rule out cable-adjustment.