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Discussion Starter #61
Yes I am unsure how all these 1.5mm plates got in there, and where they came from. It must have been recycled parts, because the doubled up steel plates at the bottom of the stack have the faint outlines of the friction pads on them, as if they were resting against a friction plate at some point and picked up some rust. Which is impossible given the order/orientation they were stacked.

But they are definitely all 1.5mm. There is no ridge between the friction surfaces and the teeth so there is no way they were ever any thicker. I checked all plates and none of them have any punch marks, all are perfectly flat when placed on a piece of glass.

The steel plates I just bought are from some sort of a 2005 Monster. A full set. When asked, the seller said they are 1.5mm, although they may have just measured one of the thin ones by chance.
 

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that looks like the newfren ones. i put a set in a customer's sf1098 on friday, will see how they go.

the aluminium tangs are much narrower than the oem ones, about the same thickness as a steel plate tang. so i'm interested to see how they pound out. i fitted them into a light steel basket, which may exaggerate it.

the 1098 packs have 8 frictions and mostly 1.5mm steels, with a couple of 2mm steels at the back. they're usually about 41.5mm thick, and the oldies are 38.5mm.
 

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Discussion Starter #64 (Edited)
So thanks to a local rider I got my hands on some extra 1.5mm driven plates. I added two to the stack for about 38mm total height. This resulted in a fair bit of clutch drag (rear wheel spins when on a stand in first with clutch pulled, neutral near impossible to engage, big clunk when shifting into first).
I bled the clutch to be sure that wasn't the problem, it made no difference. The clutch lever actually hits what feels like a hard stop about 1/4" before touching the bar, so something is bottoming out before the clutch is fully disengaged with the 38mm stack.

However a quick road check verified no more slip.

I then removed one of the extra discs for a total stack of 36.5ish mm. This solves the clutch drag issue, everything is back to normal. It got too late to check for slip though.

I have an aftermarket slave on there, not sure what brand. The engraving looks like "PI" or "IP"?

What could be the issue here? Is the slave bottoming out, and if so, why is the clutch not fully disengaged at that point? Is my clutch rod too short somehow?

Edit: ... Or maybe too much axial play in the drive shaft?
 

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"PI" is likely Pro-Italia. They are a European motorcycle dealer in the Los Angeles area. Back in the day the prior owner also made a few low volume parts. I had a PI slave on my '92 which was designed to reduce lever force with the trade-off that linear motion of the slave was also reduced. Mine worked fine with the stock clutch pack until the seals failed. I rebuilt it once and next time it failed I got a Yoyodyne.
 
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