I have managed to pick up some genuine shims and reassembled the clutch drive. I spoke to a guru who has done this quite a few times and his recommendations were; when pressure is applied to the clutch plates shifting the whole assembly against one drive plate, the opposing drive plate should spin almost freely with minimal contact against it's mating clutch. Do the same thing on the opposing drive plate. I have managed to pretty much get that spot on. All this has to be accomplished with the least amount of play for the sliding clutch assembly. Otherwise there will be too much pedal movement.
I had pretty good pedal travel on the old plates as I shimmed them up about a year ago. With new cork liners I had to fit 0.5mm of spacers to both sides. I chose to do this with two 0.25mm spacers per side for easier adjustment down the track as it wears.
Everything else looks to be good as I spent a bit of time replacing bits 18 months ago.
I need to slip the new motor in before I can test the unit out.
Last edited by aldot; 19/07/12 07:35 PM.