Clutch Worn?

The rms have weak clutches and you have done well to last this long-most people go with a hard anodised setup like a Hinson assembly-however dont use kevlar plates on a hinson clutch as they dont work well.

Hi Jason - welcome to DRN. First piece of advice - don't use all caps as caps are used to scream things :)

Next, yes it sounds like the clutch may need some work if you have adjusted both the lever play and cable play and still have very little clutch play. I would pop off the clutch cover (usually have to remove the rear brake lever and take out several 8mm bolts on the clutch cover) and check it out. Next, remove the 10mm bolts in the clutch springs and take off the pressure plate (the bolts/springs hold the plate onto the inner hub). Now, remove the clutch plates (fibers and steels) and keep them in order. Inspect the baskets (inner and outer) for notching/grooves and inspect the plates for worn spots, burnt spots, cracks, chips, etc. Chances are that your basket(s) are notched up and need to be filed down or replaced. Depending on the condition of the plates, I would recommend replacing them, too (along with the springs).

These are guesses... if you need to replace everything: outer basket ($90-130), inner hub ($30-50), steel and fiber plates and springs ($80-120), pressure plate ($20-40), misc bearings, washers, gaskets, bolts, nuts ($10-40).

Jason: before you do anything, go an buy a manual and some of these

http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=47257

if you are gonna start maintaining that bike, this will be the best $20 ever spent! mine has paid for itself many times over