Clutch stack

[Jacobrobertson2010]

I have a 2004 pro jr and am looking to stack the washers to get the best hit out of it. I don't know how they are supposed to be stacked and just looking for a few ways to get the most hit out of the bike. My boy is just ready for a lil more power. Thanks.

[Jacobrobertson2010]

So no one knows how to stack Washers in a clutch.

[bajadog]

I don't do mini's but here is a post from a mini site.

"First off not all clutch washers are the same size. Even a new bag of 1000 washers comes with variable size washers in it. It is not the size of the individual washer that matters. However, it is crucial that all overall washer stacks are the same height! Second it is important to start with good washers. T H Racing offers washers that last longer and are less resistant to heat related breakdown over the stock washers.

The taller the washer stack the higher the engine stalls (more RPMS) before the clutch engages. The lower the washer stack the sooner the clutch engages (too early will create a bog). There is a fine line between getting the bike to engage at its best and overdoing it and causing clutch drums to break.

To setup a clutch properly you will need a set of calipers to measure the stack height. I have seen inexpensive plastic ones in the auto parts stores for around $5.00.

I normally setup racing clutches to an overall height of .650 - .690 depending on the rider’s weight and track type. If you stay in that range you should be happy with the results. A good place to start would be if your rider weighs 50 pounds stay around .650, 60 pounds .670, over 65 pounds go for the .690 setup. I am calling the overall height that of all the cupped washers and flat washers together.

Now we get into the options. A setup that uses a () setup vs a (()) setup. A () setup will throw the clutches quicker a feel a little more responsive than a setup that used (()) washer stacks. In the warmer months a () setup seems to breakdown with heat much quicker than a (()) setup.

Suggested Summer setup – (top of bolt on this end) (())(())(())() plus the flat washers.

Suggested Winter– (top of bolt on this end) ()()()()((((((( plus the flat washers <requires an additional cupped washer>.

It is very important to ensure that ALL THREE WASHER STACKS are of equal height. If 1 or 2 clutch pads hit the drum before the others you are losing hook-up ability.

The bottom line is you will normally need to experiment to get YOUR RIDERS clutches they way they want it. Use the suggestions above as a good STARTING POINT. Clean your clutch washers often. The difference in a holeshot and no-holeshot is greatly due to the clutch"