Scooterotica

ive found out a fault that causes clutch slip and uneven pressure and plate wear
the clutch centre boss has the spring posts that i have found can be of uneven heights as it is supplied as cast without any machining ,if you lay it on a woktop face down you can check quickly if there is any problems
its easy to assemble the springs wrong as there a little big for the pockets they sit into so watch them as can overlap easy
both issues can be seen on an assembled clutch as an uneven gap on the outer edge of the top plate retainer when the clutch spring screws are tightened down

Haha!

The reason why I am laughing is iv`e been at work for three hours measuring and machining.

I took the "spider" down 0.45mm so it sits flush with the basket,
I machined the clutch basket down 0.25mm so it would clear the bearing circlip. I measured the tolelance with an original clutch basket and the outer edge where it sits in sito was to tall, so now the only play I have is from the brass bush.

I measured the posts and not one was the same hight!

Not having a measurment to go by I had to file the posts one at a time to match the lowest.

So after racking my brains for a few hours I come home to your reply Darrell. Almost annoying

So, tomorrow I`ll throw it all together and see if it works.

Darrell, I sent you a PM on facebook asking about your choke levers. If you have some or will knock up some more, I would like 3 please.

not seen your message on fb but have loads made up so can sort 3 out for you no problem

be careful when tightening the clutch spring bolts as the posts are also a bit weak

Fux wrote:Haha!

The reason why I am laughing is iv`e been at work for three hours measuring and machining.

I took the "spider" down 0.45mm so it sits flush with the basket,
I machined the clutch basket down 0.25mm so it would clear the bearing circlip. I measured the tolelance with an original clutch basket and the outer edge where it sits in sito was to tall, so now the only play I have is from the brass bush.

I measured the posts and not one was the same hight!

Not having a measurment to go by I had to file the posts one at a time to match the lowest.

So after racking my brains for a few hours I come home to your reply Darrell. Almost annoying

Now that really is quality

.... And great quality control too... shameful, in fact.... You must call AF and inform them of this, and maybe send an invoice for your time fixing it

The "road" clutch is cast as Darrell says, the surflex one is machined, hence the differences, Ben told me that the cast indian road clutch is not guaranteed to have the same tolerances as the surflex clutch, thats why its half the price! First Ive heard of any problems like this tho I have each version of the clutch and so does a mate of mine we have had no problems at all, but theyres a first for everything.

Enjoy the clutch they are really good.

ive had around 5 clutches and only had 2 that was causing a problem that were on higher powered motors that i was then forced to investigate so the others may be the same? ,up to around 25 bhp there fine but hadnt had 1 work above 30 but following the filing/levelling on the posts ive now seen it hold 32 so quite pleased now as they make a viable option again
ive let ben know a few months back so im sure theyll be checking them out now

Well, its not about the money.

I asked the dealer about the race clutch and he said it wasn`t neccecery because the road clutch was just as good.

I has a very nice action and it should have rung som bells that I have heard of a few they say its a bit grippy and easy to stall, where as mine felt like a sloppy vespa clutch.

It would have been nice to have some measurments to go by when I filed down the posts because I imagine if you take them down too much, you`ll end up with a unmanagable clutch.

Fux wrote:
It would have been nice to have some measurments to go by when I filed down the posts because I imagine if you take them down too much, you`ll end up with a unmanagable clutch.

you could drop some shims on top of all the posts if you file off too much and have an issue ,a spot of sealant would hold them until its assembled ,not the best idea but could get u out of the s**t

Yes!

Right, I ended up taking half a millimeter off the shortest post, mesured with a vernier caliper and filed the other 4 to match.

The clutch now sits on the bearing shim without touching the circlip and clutch basket is the same hight.

After torquing it all up the clutch play has gone apart from the "normal" bushing play.

Threw it all together and the scoot goes like stink now, without slip.

I`m well chuffed with myself. The scoot is certainly running rich when I reach full throttle but I will leave as is until after the rally and my choke lever turns up.

Now if I am lucky I my Gori race seat will turn up this week to complete this project and I can start on my Li2 TS1 when I get home. I was thinking about using an AF clutch in that too but I`m not sure now.

Rally done and dusted, 300km`s and not a problem.

The clutch, however does stil slip but less than before and only in 1st and 2nd when I give it some real stick.

I got an email from AF and the clutch posts are supposed to be 19.25mm + - 0.25.

I`ll order some new clutch plates and measure the posts and take it from there.