'79 gs1000 clutch basket flying banana spring shim rebuild

[garyS-NJ]

my clutch makes a racket in neutral at idle. I took it apart and found the shaft nut was loose but I inspected further and decided to do the flying banana spring shim basket rebuild (see https://www.theflyingbanana.com/clutchhub.htm ). has anyone on here done this rebuild?

I used thin washers to shim the heavy springs just muscling them in with my fingers and thicker washers for the light springs.

1. does this sound right or should I really be compressing the springs with pliers to get thicker washers in there?
   
2. there is a big concave thrust washer between the hub and the backer plate. It fell out when I took off the backer plate so I don't know which way the washer lays. does the high side (inside edge of washer) face up towards the backer plate or down towards the hub? I looked at the hub and backer plate for wear marks which might tell me which way to install the washer and I think the high inner edge goes up towards the backer plate. I did observe some gauling on the hub at the thrust washer surface but decided to use it and hope for the best.
   
3. the rivets have a sleeve which is interference fit to the rivet and the rivet is now backed out of the sleeve a little. I planned to press the sleeve down to pinch the rivet to the hub and then drop on the backer plate and tack weld the center rivet to the backer plate. I have a 90 amp harbor freight wire feed welded and was going to tack the rivet to the plate and hope I don't blast through it. sound reasonable??

 

[garyS-NJ]

I did it. Seems I can only upload one pic here so I'm putting in the completed job

 

[londonboards]

Your pic looks odd.

Where is the clutch basket?

The rivets hold the clutch basket on.

 

[garyS-NJ]

Thanks rich. It was just a crappy pic. I put it together same as it came apart. Is that a APE moded basket? They put some Mongo welds... I think I'm going to need mine up (I was worried about burning through the plate. But while its off, are anyone doing any other mods like drilling holes to allow more oil to keep clutch cooler like this video for a dirt bike clutch.. https://youtu.be/PivPwYZRNWU

 

[garyS-NJ]

Well. I got it together today. Lost a clutch cover centering bushing and after hunting all over, found it in my alley. Clutch quiet as a church mouse. I can do this upgrade for a reasonable price. Then I cut my new dirt bike handlebars shorter and broke the throttle slide. Hunted all over and found two but they were single cable. Threw in the gs towel. Bought a beer and taking the katana to sturgis. Waiting for my buddy, beaten.

 

[garyS-NJ]

back from Sturgis with a swap meet throttle tube and got the GS1000 rolling yesterday. I trimmed the bars another 3/8" shorter and once rolling I found the clutch NOT disengaging well enough to find neutral at stop and shifting a little hard. I threaded the top lever adjuster out to almost no play but it didn't get better. I can only suspect I cramped the cable routeing when pushing the perch further inboard. Note that I do have the cable routed forward of the carbs. The clutch always grabbed kinda far out. when I did the basket, I looked at the plates and they looked fine but I didn't measure. suggestions??

 

[GregT]

Back the cable right off and pull off the short lever on top of the shaft in the clutch cover. It's on a spline. Move it round one spline - away from the cable anchor.
This should put your cable adjuster back in the center of it's range.

 

[garyS-NJ]

Thanks. Yes, logical, and I thought I put it together same as before but yesterday looked and saw I was off a few spines from square.