I have reassembled the clutch with a new drum and friction plate. I checked the plunger springs and all seems to be well in that area. Attached are three photos of the old drum showing the wear in the slots, the thin-walled carrier (for Timetraveller's benefit) and finally, the odd asymmetry of the inner plain clutch plate (C21) that I recently discovered. The tabs on the old friction plate were also well worn.
In addition to the wear in the drum slots and the tabs on the friction plate, I noticed that one of the clutch springs was hanging up in its cup (C30). It had a burr and some roughness. To cure that, I sanded the inside of the cup with a little Dremel sanding drum. It seems OK now. Then I had to work on the tabs on the new friction plate. They were all about .006" wider than the slots in the new drum. I mounted the plate in soft plastic jaws of a vise and filed one at a time, counting strokes of the file on each tab, measuring, filing etc. working both sides of each tab, little by little. You get the idea I'm sure. The plate is now a nice snug fit without binding and no noticeable backlash.
Now the problem with the inner plain plate. The 9 holes for the pins are not properly centered in the plate which sets the plate off by maybe 1/16", as can be seen in the photo. It almost touches the drum on one side in the 4 O'clock position in the photo. It appears to be touching in the photo but there is some clearance. I'm guessing it isn't critical but I'd appreciate any thoughts on the subject. The plate is flat.
I can't report the results on the road yet. We're buried in snow at the moment and a lot more is on the way. Spring can't come soon enough.
In addition to the wear in the drum slots and the tabs on the friction plate, I noticed that one of the clutch springs was hanging up in its cup (C30). It had a burr and some roughness. To cure that, I sanded the inside of the cup with a little Dremel sanding drum. It seems OK now. Then I had to work on the tabs on the new friction plate. They were all about .006" wider than the slots in the new drum. I mounted the plate in soft plastic jaws of a vise and filed one at a time, counting strokes of the file on each tab, measuring, filing etc. working both sides of each tab, little by little. You get the idea I'm sure. The plate is now a nice snug fit without binding and no noticeable backlash.
Now the problem with the inner plain plate. The 9 holes for the pins are not properly centered in the plate which sets the plate off by maybe 1/16", as can be seen in the photo. It almost touches the drum on one side in the 4 O'clock position in the photo. It appears to be touching in the photo but there is some clearance. I'm guessing it isn't critical but I'd appreciate any thoughts on the subject. The plate is flat.
I can't report the results on the road yet. We're buried in snow at the moment and a lot more is on the way. Spring can't come soon enough.