back home and Mule first up to see what is going on with the clutch, it was still slipping like normal banging down the gears going into corners and locking up as it should under power but we could not get the clutch to release with lever fully in
Plus the lever went hard when pulled it into the bars due to increased hydraulic pressure, bit odd
Drained the oil, no metal on the magnetic sump plug, good sign, pulled Primary cover off, all looked good so far
Removed the Clutch basket and found one of the needle rollers had escaped from the clutch support needle roller bearing in the Primary cover and had found its way into the area between the inside of the Clutch Basket and the front of the Pressure plate thus stopping the Pressure plate from fully opening which would have happened when I installed the Primary cover after the last rebuild
Hence no clutch but we still had enough movement in the pressure plate to separate enough to allow it to slip during corner entry
Slipper clutch exposed, no sign of any damage
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The offending needle roller, 2.5mm diameter, enough to stop the clutch from working
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Opened the Slipper clutch anyway to check everything was as it should be, all good
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Bike back together and ready to leave for Darwin, Leak down test done and passed, new oil, labelled the tyres so I know what work they have done
Very pleased it was a simple fix
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