Trouble With Vulcan 1500 Clutch Replacement

rebeltaz · Renault 5 Driver Joined: 02 Jul 2005 Karma :

I am replacing the clutches on a 2002 Vulcan VN1500 Classic FI. When it came in, the clutches were slipping BAD. When I took it apart, the metal discs were burnt and there is a distinctive smell of, what smells like to me, hickory. The torque limiter springs were installed incorrectly and one of them is way out of shape. After replacing the friction plates, the metal plates and the torque limiter springs, I went to put everything back together. The operating plate sticks out too far to insert the clip into the retaining groove of the clutch cover. I have found that if I loosen the clutch hub nut quite a bit, then the operating plate will fit. I know that there are larger steel plates, but the service manual only recommends replacing one with an adjustment plate and to be honest, the extra 0.3mm is not going to be anywhere near enough to account for the difference I need.

Also, in the service manual, it says to squeeze the clutch handle while you insert the spring plate pusher. That doesn't really make any sense since pulling the clutch lever in pushes the pusher out!

It's been a long day. What am I missing here?
____________________
Derek Tombrello
www.ShelbyCycle.com (for profit)
www.RobotsAndComputers.com (just for fun)

sickpup · Old Timer Joined: 21 Apr 2004 Karma :

Have you measured the clutch stack heaight and compared it to the manual?

rebeltaz · Renault 5 Driver Joined: 02 Jul 2005 Karma :

I didn't compare it to the manual, but I did compare it to the stack I pulled out and both were the same.
____________________
Derek Tombrello
www.ShelbyCycle.com (for profit)
www.RobotsAndComputers.com (just for fun)

Sister Sledge · World Chat Champion Joined: 17 Aug 2018 Karma :

I'm completely in the dark with the bike in question but the clutch seems to have a hydraulic mechanism?
Could the hydraulic mechanism have moved a little just like car brake calipers can when the pads are out? I know sometimes you have to shove the pistons back on calipers to get the pads back in (not necessarily new pads)

I could also be way off track.

rebeltaz · Renault 5 Driver Joined: 02 Jul 2005 Karma :

It is hydraulic. The slave cylinder seems to be inside the engine, but I am going to try shoving the push rod back in tomorrow. Hopefully that is all it is. I'm just always scared to push (or pull) to hard on things. I have a tendency to break things!
____________________
Derek Tombrello
www.ShelbyCycle.com (for profit)
www.RobotsAndComputers.com (just for fun)