Eqcons,
The clutch lever is the only thing left that has not been inspected or changed on my bike. Give it a shot!
Well, it's been a while since I had work completed on my clutch issue.
1) Replaced the Master Cylinder
2) Replaced the clutch pack
3) Measured the throw of the slave (or secondary) cylinder
At first, mine was back to the way it was when I purchased the bike. Now with a few more K on it, the clutch engages further out and is not as linear.
Bear with me as this may be a little hard to explain in writing.
A couple of things I noticed:
1) Before the replacement parts and with the clutch fully engaged (lever all the way out) when I began to pull the clutch to change gear, it felt like the clutch system was binding. Not smooth at the beginning of the pull to disengage the clutch. Felt a little chunky. This went away after the master cylinder and clutch pack was replaced and now it is back. I did not notice this when the bike was new. Then after a few K, I did notice it. When the parts were replaced, this "binding" went away. Now it's back.
2) When the bike was new, I did not feel the clunk into gear in the clutch lever (1st to 2nd and 3rd, etc). After a few K, I did. Then when the parts were replaced, I was not able to feel the shift in the lever. After a few K, I can again. Don't get me wrong, I feel it in the whole bike but more so in the lever itself.
Because the changes to the clutch are gradual, the main reason I noticed these two things is that it has happened twice on this bike. And, of course, I am paying close attention to the clutch. Otherwise I will drop it in a tight turn! (That would make twice)
I wonder if the excessive wear reported on the original clutch was due to binding in the cage. (not the clutch itself, but there was excessive wear at the points that the clutch pack rides in the cage). Sorry to all of you techs if I described that wrong.
Thanks for everyone's input.
Eqcons, there is something not right with our bikes. Other hydraulic bikes feel nothing like mine.
Question: Does yours once in a while catch you off guard? I mean, engage in a location that is not in the "normal" position for your bike? Mine does and it shocks the crap out of me each time. The bike launches and I have to pull the clutch back in and start over. Only once in a while though. Wondering if it's me or not.