GSX-R1100 Diaphragm Spring Clutch Springs

[eramljak]

My clutch parts finally arrived from The Netherlands. I live in Canada, so it's a pretty big deal. I had to wait over 3 weeks! 

 

Everything is back together and pulling strong, I just wanted to post some pics of worn out vs new.  The clutch action does feel much smoother and I do feel safer knowing that my clutch is less likely to break.

I'm using a cable operated clutch actuator (screw assembly) from GSX600F.

Look how close I was to dying!!! This pivot point should not move at all, but I have about 2mm of play

Fresh and clean. This is mounted on top of 2 x 1mm thick washers to bring the actuator closer to the clutch push rod, so that I have better engagement.

Next up, the spring seat. this was actually in pretty good shape, but was showing some wear and I thought "what the hell, it's only money!" 

The springs ride on the outside edge of this seat. I imagine that there is a very small amount of movement as the springs are compressed.

the new one has the spots on it / is the one higher up in the picture. both of them measured at 1.7mm, so I'm sure it would have been fine to not replace it.

Springs; these were the most worn parts in the kit. There was extreme wear on the inside diameter of the springs, with more wear on one spring than the other. The inside is the part seated against the big 50mm nut holding the pressure at 100Nm 

The outside edges did show some wear. old spring is higher in the picture, new spring is lower.

old springs:

Old springs measured at : 3mm and 3.2mm the new springs were 3.34mm. The spec requires a minimum of 3.1mm spring height. All the same, I did replace both springs with new ones.

 

And adding everything up tells a big story: how thick is a seat and two springs after a harsh 30 year service run?

5.94mm, seems pretty good, but what about new?

6.18mm!

Only 0.24mm difference. That is the difference between working properly and losing power to the wheel at 4500RPM. Incredible!

Another part seeing wear is the first installed steel plate. this comes up against the "wave washer" AKA the anti shudder spring.  The spring itself is in good health, but it managed to wear a good gouge into the steel plate: