Clutch shim placement

[thormagnus]

Hi all,

Been about a year since the origninal posting about dad's bike and Jon and I have got a lot done! Almost everything has been either replaced or cleaned and we finally found all the right parts to get her running again. We still have some general electric stuff to clean up, get the clocks working correctly, and are struggling the clutch now. Specifically, shimming it.

The previous post to this one addresses a similar problem but
http://www.morini-riders-club.com/thebi ... lutch.html
isn't clear to us. We understand it needs to be shimmed but we don't have a brass or nylon washer. Should we need one at all '75 350 Sport?

The big question is: where exactly does the shim go? We have clutch basket movement in-and-out measured to 1.52mm but is it behind the clutch basket that we place the shim or?? What is the "clutch centre"? Is it the outer basket or inner housing outside of the clutch cover? Or inside the block behind the clutch cover?

Also, the bolts from the clutch basket to the gear are digging into the block. Are we missing a washer? Is that normal or will it be addressed with the shim?

Below is a picture of everything we have, thoughts?




Thanks for all the continued help. We've been taking pictures as we go and my goal is to create a site/blog once this is all said and done to share the whole journey with every one.

Cheers!

Wes

[3potjohn]

The upper photo shows the outer clutch basket 2nd down on the right.In the central part should be a washer,with 4 lobes, white nylon material or on earlier bikes it was brass.I cannot see it in the pictures.
see this link showing a brass and the better nylon washer
http://www.flickr.com/photos/57997293@N ... /lightbox/
Best of luck refitting the kickstart by the way, it is something I have done twice but not very well.

[thormagnus]

Thanks! See, that's my question too: Does that mean that all bikes should have some sort of washer, brass or nylon? This does not have either. Off the clutch link on the website I read it as that there might be some models that have neither. Is there some sort of breakdown as to which models have which? Right now we have no washer.

The kickstart was a little tricky but it seems to go on nicely now.

[3potjohn]

The white nylon large washer with 4 lobes,which sit in the 4 recessed bolt positions is needed otherwise the clutch centre will not have anything on which to rotate other than metal from the clutch basket outer, which is not correct, either in operation nor when trying to eliminate end float by using a shim.You must get one of these washers!
Good luck. John

[thormagnus]

Thanks John!

Jon ordered a replacement copper washer and new spring bolts from Herdan yesterday. Hopefully those will help solve the problem and if not we'll shim until fit. Will update once it's all on. Probably a week to receive parts.

Cheers!

Wes