when changing down gears the change is slightly clunky, Going up the gears in fine. When you tweet the throttle going down the gears a clicking noise is heard from the bottom end/Drive spindle area and the chain flaps giving a clunky gear change, this happens with the clutch lever fully pulled in. Giving me the impression that the clutch is not fully dis-engaging ??? I have taken the clutch apart and my local shop says its fine.
The cable is correctly adjusted and has been checked by a local garage and the chain tension is fine. The bike is an 05 plate and has only done 5k miles so there should not be any worn parts really.
When the bike is cold it does not really happen but as soon as its up to temp it does it.

Could I have a Clutch Swell problem ???

Any Help would be appreciated.

Grant

 

I don't understand some of your terminology, but it sounds like your having issues with the bike clunking downshifting even with the clutch pulled in. it also does this when the bike is simply rev'd up with the clutch pulled in. Is this correct?

Can you feel the clunk? or just hear it? Do you feel any surging?

If so, a little movement is not uncommon. For example, if your bike is on a rear stand, even in neutral, if you rev the engine, the rear wheel will begin to turn. Its not a lot, but it does turn. It also does this in gear with the clutch pulled in.

However, I have never had clunking or so much movement that it was noticable with the wheels on the ground.

What type of oil are you running? Its possible you may have dirty oil or improper oil. If the wrong oil is used, it can cause the clutch plates to swell and stick. Dirty oil can cause issues as well.

 

Sometimes when i am shifting into 1st gear coming to a stop the tranny makes a pretty bad grinding noise... Sometimes I can tell when its going to happen by putting pressure on the shifter and if it fels like its gonna happen i reengage the clutcha bit then try shifting again.

 

I get the same thing as Michaud. Wonder if it is my clutch going or it is normal to hear some "winding down" sorta grinding noise when down shifting at slow speeds.

 

If I were you (which I'm not, nor am I a mechanic haha) I would adjust tension on the cable even further down by the clutch basket casing (not the lever on the handle bars) so that the clutch is disengaged VERY SLIGHTLY in it's resting position. Ride it around a little bit with the new tension adjustments just to see if you can get it to exhibit the behavior of a fully disengaged clutch, even if it is with cable tension bordering on the absurd. It could also be the oil viscosity. If the oil is too thick, it's not going to allow for the necessary slipping between pressure plates in the basket when the clutch is disengaged. If the oil is to "oily" it's not going to allow the pressure plates to grip each other when the clutch is fully engaged. I don't know what to think about any "grinding" sound. That seems more exclusively transmission related than clutch related. I know that there may be a distinct "whining" noise when in gear with the clutch disengaged that sounds similar to this: Supercharged Cadillac STS-V Supercharger Whine / Scream - YouTube but that's due to the straight-cut gears in the transmission as opposed to helical-cut gears in most road cars. Also, keep in mind that a certain degree of clunkiness is going to be unavoidable while downshifting if there is a considerable gap in your rev matching.