My clutch has been acting funny for about a month now - feeling like there's air in the line, & chattery when not engaged. I've bled it several times, which makes it ok for a little while, but it deteriorates pretty quickly. I figured the slave was on its way out; when I fixed the the bleed screw last month, the seal on the slave piston looked pretty worn & its been since then that's been degrading pretty rapidly.

So today, I have almost all the parts I need (waiting on a new mushroom pin, although I could re-use the original, but since the new one will be here, I might as well wait) - I figured I'd take it apart, clean it all up and measure the clutch pack - in the event it could stand for new plates while I wait for the pin.

1st, the picture (attached) - this was the stock clutch pin I pulled out. Catastrophic bearing failure. I guess that explains the chattering and weak feel at the lever!

Next question: I measured the plates (friction disc et al) at about 30.3-30.5mm. So it's down about 3mm . I suppose I could order a new clutch pack, since I'm in there and replacing everything else already - but what's the minimum thickness for the pack?

There are posts here ( Faq,s , I think ) that shows how to fit the later slave piston and seal ( off the SS ), which is a better set up . Chattering can be caused by dirty plates . Any sign of black sticky stuff needs to be cleaned off , and have a look at the seals around the primary drive gear and the input shaft , even a small weep here is enough to dirty the plates ...... and then your back to the chattery , grabby , dragging clutch ......which makes it a bitch round town ( I would rather try to escort a whole class of special needs kids thru a toy shop )