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post #1 of 7 (permalink) Old 06-06-2019, 09:52 PM Thread Starter
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Spring Limiter Installation Issues

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

Spring Limiter Installation Issues-img_1713.jpg
First the clutch basket was installed on the transmission shaft

Spring Limiter Installation Issues-spacer.jpg
Followed by the spacer, beveled side faced outwards

Spring Limiter Installation Issues-img_1715.jpg

Spring Limiter Installation Issues-img_1716.jpg
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

Spring Limiter Installation Issues-img_1720.jpg
Now the clutch hub no longer sits flush against the fibers of the first plate

Edit: This is on a 2006 ZX6R

2005 ZX6R Trackbike w/Penske, AK20s, Akra
$1000 2006 ZX6 Project Bike

Last edited by Rowcha; 06-06-2019 at 10:08 PM.
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post #2 of 7 (permalink) Old 06-06-2019, 10:03 PM Thread Starter
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Spring Limiter Installation Issues-img_1718.jpg
The spring plate sits correctly when the rest of the parts are not installed

Spring Limiter Installation Issues-img_1722.jpg
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

2005 ZX6R Trackbike w/Penske, AK20s, Akra
$1000 2006 ZX6 Project Bike
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post #3 of 7 (permalink) Old 06-11-2019, 12:33 AM
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sell me the bike or check your stack height

if i die at 150 tell em i was smile n and headed for living170

life around 160
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post #4 of 7 (permalink) Old 06-12-2019, 03:03 PM Thread Starter
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Quote:
Originally Posted by zx6rmotard View Post
sell me the bike or check your stack height

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

2005 ZX6R Trackbike w/Penske, AK20s, Akra
$1000 2006 ZX6 Project Bike
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post #5 of 7 (permalink) Old 06-12-2019, 04:46 PM
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did u mic the stack height

if i die at 150 tell em i was smile n and headed for living170

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post #6 of 7 (permalink) Old 06-13-2019, 04:25 PM Thread Starter
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Quote:
Originally Posted by zx6rmotard View Post
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?
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2005 ZX6R Trackbike w/Penske, AK20s, Akra
$1000 2006 ZX6 Project Bike
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post #7 of 7 (permalink) Old 06-16-2019, 09:06 PM
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Quote:
Originally Posted by Rowcha View Post
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.
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