Need some input from the collective geniuses here guys. I've forgotten more than I care to admit but I have a problem now so I thought I'd ask.
Rode bike through town the other day and suddenly when leaving a stop light my shifts were hard.
Before I go any further here's my setup.
2004 FLSTCI with a Energy One Extra Plate clutch. 10mm ***** in the Ball n Ramp assy. Redline Heavy Shockproof in the Tranny and B&M Trick Shift in the Primary per Energy One recommendations. About 1000 miles on the setup.
Primary level is correct and chain is 5/8" to 3/4". Checked in 4 spots. Drive belt is set and I can flex it 45 degrees. The transmission level is correct. The fluids appear to be good by visual and finger rub.
Adjusted clutch as I always have and it still shifts hard. Measure clutch plate lift and have plenty at .095" to .098". Minimal is .080" I believe.
I'm stumped. Any ideas? Try changing fluids?
Lastly, trying to adjust with clutch temp at 100⁰ F. Using Laser Temp Gun on pushrod and nut. It's hot here.
I'll also add I have a manual primary chain adjuster and the clutch lever free play is a dime's worth. And it creeps a bit when starting in gear. But it has plenty of lift! Arrgh!

 

If you can find neutral but other gears an issue, look at the shift linkage..

 

I've rarely been able to get Neutral at a stop from 1st ever since I installed this clutch setup. I've just learned to hit Neutral from 2nd. And shifting was no problem.
The shift linkage all appears good and tight. With measuring the lift I have at the diaphragm and still having a bit of drag I'm now wondering about the Pushrod or Throw Out Bearing. I just ordered 13/64" ball bearings to replace the 10 mm one's in the ramp assy. My clutch adjustment is out 1/8th turn. I'm baffled and grasping.

 

Does the +1 clutch use the damping spring and spacer or are they removed?

Maybe the motor is bleeding into the primary. What is the primary level?

 

They're removed. It's been fine for a good while. The primary level is perfect. I'm sure it's not bleeding.

 

So if you jack the back wheel up and rock it back and forth, does the tranny shift through the gears fine..

Have you thought about trying a new clutch pack..

When I build my 07 egc to 107, the clutch started slipping.. Frictions had about 50000 miles on them, stock plate count barnett kevlar. I replaced with a new set of frictions and the clutch stopped slipping. The bike became a lot easier to find neutral..

DId it shift hard before you did the clutch?

You say that you've measured the lift. Have you tried it at say the outer edge of the pressure plate and a few different points? Maybe it's not lifting straight?

 

Note any grooves in the basket, or the hub splines, when you replaced the clutch plates?

 

Did you replace the steel plates when you did the clutch? I had a dragging clutch and couldn't figure it out. Ended up being one steel disc had a slight dish to it and was just enough to cause it to drag. If you haven't already, I'd check them for flatness closely

 

No that was all good.

 

Oh yeah. Been there done that! Had a warped Alto before.