[Rowcha]

I recently removed this engine, split the cases, and replaced the transmission input and output shafts. While reassembling the clutch— my spring plate does not mate correctly with the clutch hub. I believe this is due to the torque limiter springs as they are contacting the hub. I was sure to align the notches in the spring plate with the notches in the hub, per the manual. I also believe I installed all related parts correctly. Does anyone have experience installing these springs?

Here is how I installed everything


First the clutch basket was installed on the transmission shaft


Followed by the spacer, beveled side faced outwards




Hub, torque limiter springs, and nut installed. I installed the springs in the correct order per the service manual. In this picture the springs lay flat as the nut has not been torqued to spec. However when i tighten the nut, the springs bend upwards, interfering with the spring plate


Now the clutch hub no longer sits flush against the fibers of the first plate

Edit: This is on a 2006 ZX6R

 

[Rowcha]

The spring plate sits correctly when the rest of the parts are not installed


Note the wear on the spring plate from the springs

I'm really scratching my head here, from what i can tell I've installed everything correctly. I've closely followed the service manual but I cannot seem to get this right

 

[zx6rmotard]

sell me the bike or check your stack height

 

[Rowcha]

sell me the bike or check your stack height

My bike is not for sale. And the stack height is not the issue.

 

[zx6rmotard]

did u mic the stack height

 

[Rowcha]

did u mic the stack height

Again, I don’t think stack height is the issue. Standard is 39.1mm.

Could anyone that’s installed a clutch hub shed some light here?

 

[killer2600]

View attachment 131633
Hub, torque limiter springs, and nut installed. I installed the springs in the correct order per the service manual. In this picture the springs lay flat as the nut has not been torqued to spec. However when i tighten the nut, the springs bend upwards, interfering with the spring plate
Edit: This is on a 2006 ZX6R

From the looks of it, the torque limiter springs are in the wrong location.