Karata 4" Open Primary Q

[pknowles]

Have about 17000 miles on mine but I installed EFM auto clutch shortly after, had problems with metal clutch plates cutting into clutch housing and then I installed aluminum plates, I put a how to on this website about installing open primary and showed pictures of plates

Thanks for posting, I'm sure Rick will be looking it up.

 

[PacoPetty]

Thanks Doug. I knew the values were low. I was going with 10 ft bs.
I opened it up again and this time pulled the pressure plate and clutch pack out. Here is the problem:
View attachment 60224
The splines on the friction plates have worn grooves all the way around the drum. I’m looking at it and now see how the friction plates would get stuck on the grooves and not be able to slide back and forth with the clutch lever. You pull on the cutch lever and the plates say ‘I don’t think so—I’m in a groove here.’
Dunno what the drum and new clutch pack is gonna cost me, but I’m not happy.
Going now to get the impact wrench and set to left hand threads to get the basket off to prepare for replacement.

That sucks!

 

[pauldeepsea]

That post is really on point, Doug--thanks. You're correct--Jim told me there was a redesign a couple of years ago.
What torque specs did you set? I haven't found any other than adapting what is in the BDM Manual.
I cannot believe the springs and plates could be worn out with so few miles, and am confident Trainguy (DJ) did not abuse it. However they are several years old.
The clutch cable might be it, as Paul suggests, but its operation so far has been smooth and flawless.....DJ notes that was the first time it was in the rain!
If the springs were an issue, I'd think it would slip, and it doesn't. That's why pulling the pressure plate seems like what needs to happen next.

I spoke to Jim and I know others will chime in but I agree with him on this one, I use a a Milwaukee impact wrench and red loctite. I get the nut walked on by hand and use the impact wrench. I run it down until I get a few good .. zap , zaps on the wrench. I think that’s the way Jim described it lol. No shit it works and I am usually the anal bastard when it come to torque specifications.


Sent from my iPhone using Tapatalk

 

[Trainguy]

I'm no mechanic but I think the bike is Pissed Off. It's been sitting on a bike lift for two years, in a year round controlled environment listening to rock & roll an watching video's ( Clapton, Seger, Eagles, Stones, Petty, that's Led Zep on the video right now ). Then this guy shows up from Kansas an it all changed...…….

 

[SKOGDOG]

I'm no mechanic by I think the bike is Pissed Off. It's been sitting on a bike lift for two years in a year round controlled environment listening to rock & roll an watching video's ( Clapton, Seger, Eagles, Stones, Petty ). Then this guy shows up from Kansas an it all changed...…….

A pissed off K9....good one!! That bike is made to run like a greyhound!! Long, sleek, and built to cruise all day at 80. This primary issue is but a hiccup from needing exercise. But seriously, I want to come back in the next life as one of Trainguy's motorcycles---a pampered existence and all needs met with infrequent performance demands. Haha
I have everything ready for the new parts install...it's disassembled, bolts cleaned so they will torque correctly. If the parts arrive on Monday, it will be back on the road that evening.
Doug BDM 7250 has posted some very helpful videos and gave me a lot of good info by phone this morning. He has many trouble-free touring miles.

 

[TapioK]

Wow, having friction plates that much harder material than basket is not the best engineering...

 

[bdm7250]

Wow, having friction plates that much harder material than basket is not the best engineering...

Prolly why they made the change.

 

[Brew]

I'm a recipient of the old clutch basket. Mine did the same as yours Rick, it developed the groves and fully didn't release. I called Jim about it and wasn't too happy with his answer and bought the new basket with clutch and friction plates. This was about two years ago so it cost me 400 bucks. So far no issues and I don't see any groves developing on the new hardened basket. I still love my Karata 4" though.

 

[SKOGDOG]

I'm a recipient of the old clutch basket. Mine did the same as yours Rick, it developed the groves and fully didn't release. I called Jim about it and wasn't too happy with his answer and bought the new basket with clutch and friction plates. This was about two years ago so it cost me 400 bucks. So far no issues and I don't see any groves developing on the new hardened basket. I still love my Karata 4" though.

Thanks Rob--It cost me a couple of hundred more than that. Jim implied that the prior owner or I had a riding style of lugging the engine that made that failure happen. I reject that.
The Karata drum failed due to materials engineering at less than 4000 miles. Either the ears on the clutch friction plates are too hard, or the drum is too soft. That should not happen no matter what. And although I ride hard (sustained high speed) but do not slam gears or lug the engine.
But like you, I will be happy enough if the new basket holds up--Jim assures me this is the case.
I truly hope it goes well, as I love everything about the Karata except when I let out the clutch lever it drags my ass across the street or parking lot. Once the discs find the grooves and are pulling weight, no way they'll release, no matter how hard you pull the clutch lever. You have to hit the kill switch.
Here's an image of my old drum...

 

[Rottweiler]

Sounds like it should be fixed at no cost.

Sent from my Life One X3 using Tapatalk

 

[pknowles]

Sounds like it should be fixed at no cost.

Sent from my Life One X3 using Tapatalk

I doubt there's a warranty on anything that old. Baker

 

[SKOGDOG]

Jim at Karata would not replace anything and insisted that either me or prior owner lugging the engine causes such damage.
In his defense I didn't buy the open primary from Karata--it was on the bike I purchased. The bike only had 4600 miles and the Karata had less than that, so I hoped he would at least sell at cost or a discount. No dice.
The re-designed basket and clutch pac are installed and working fine after a couple of hundred miles. I probably won't know until next spring after a few thousand miles. Believe me I will let everyone know how it goes.

 

[bdm7250]

Jim at Karata would not replace anything and insisted that either me or prior owner lugging the engine causes such damage.
In his defense I didn't buy the open primary from Karata--it was on the bike I purchased. The bike only had 4600 miles and the Karata had less than that, so I hoped he would at least sell at cost or a discount. No dice.
The re-designed basket and clutch pac are installed and working fine after a couple of hundred miles. I probably won't know until next spring after a few thousand miles. Believe me I will let everyone know how it goes.

I'll be willing to bet that it looks like this when you get it apart, if you zoom in on the pics, you can see slight wear in the clutch plates, nothing on the basket..