Final thoughts and lessons learned.
I ordered the rebuild kit from RMATV. The OEM parts list was a little confusing about what was included. Some of the parts indicated they were in the kit, but other parts did not. I ordered the cover gasket since it did not say it was part of the kit. It was so I now have an extra. The Kit includes all the friction and clutch plates, the cover gasket, and the wire circlip.
Check all contents in the kit box. Check the inventory against the parts diagram to confirm what you got. I missed the back plate, stuck in the box.
In my initial install the clutch action was weak. I don't know if air somehow got in with the pressure release, but I had to bleed the clutch to restore full motion. That's when I made the mistake and closed the reservoir with it too full. Pressure could not release fully, and that resulted in significant slippage. Correcting the level would have fixed it but I needed to add that last new plate.
As many times as I have removed and replaced the Clutch cover, I never paid attention to the screw tightening sequence. Got it memorized now. Doing it properly will probably improve chances of reusing the gasket. For some reason I needed to remove the header heat shield to clear the cover this time.
I did not measure all of the old plates. I measured one that was slightly under spec so that was good enough to proceed. I will go back and measure them all at some point. For 112K things looked pretty good. The spring was just under max spec.
