Clutch fitting woes

[del mar]

Evening,

Clutch was slipping and there was no adjustment left on the cable, so I thought I would give it a go -900 diversion.

Haynes manual looks straight forward.

I have refitted new clutch friction discs and bought a new Yamaha cable.

The clutch is either not engaging or disengaging.

If the bike is in gear and you pull the clutch lever in or manually push the lever on the clutch cover it won’t move. The levers appear to have no effect.

It moves freely in neutral.

I soaked the plates in oil and counted the old ones out and the new ones in.

The manual says you need a tool - or improvised one to hold the clutch case while you tighten the spring bolts, but the clutch appears so tight I don’t need the tool.

What has gone wrong ?

Thanks

Del

[Benni]

Te classic would be that the last of the old metal discs remained unnoticed way back in the basket,
and now you have one disc too many in the basket, this could be a reason for clutch not disengaging / opening.

Were there any spacers / bushings under or inside the basket,
and did you refit them in the exact position there were before ?

Just guessing, from my way-back-when experience as bike mechanic, been there before.

[jjones]

Usually the last one you put in is offset to all the ones you stacked in before. Might be worth checking the manual that this is the case and that you have the last in disc in the right location.

[bimsb6]

Does the pressure plate have to fit in a specific location on those ?

[del mar]

Thank you gentlemen, will have a look tonight to see if there are 1 too many discs.

The pressure plate has two marks on it with need to be aligned.

Del