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1/ First check operating arm at gearbox end has freeplay not just cable. Adjuster for this is behind thrust washer on arm itself. this is my guess at problem2/ Thrust washer will scream if shot, not your immediate problem3/ Washing plates only relevant if soaked in oil, obvious because puddle of oil under bell housing when parkedThereforeIf not adjustment in 1, your problem is internal, can only be fixed by dismantling. Perhaps one plate has sheered it's revitts as Guzzista did or both worn out from no freeplay. Spline damage unlikely IMHO but of course will be obvious when apart.2 new friction plates probably all that's needed (and a day of grunt). New thrust washer prob wise but inspect first, if perfect to look at, it is.
My experience with 3 Calis ( 1100 I, EV and lastly 1100 carbie) is as follows. In the first 2 cases one of the clutch discs sheared off the splined section at about 40 k miles . No clutch wear/ weird slack at lever or anything sticking out at the clutch plunger body on the back of the tranny but... Slippage with power application at about 4500 rpm +. Only solution was to replace the clutch parts.My last Cali , a low mileage 1994 carb bike, had the gearbox overfilled by the PO, resulting in slippage. After removing the clutch plunger, pushrod, as well as hosing down the clutch assembly with paint thinner, reassemble and replaced cone seals on pushrod. After refilling to correct level, the bike was ridden on the freeway and throttle rolled on to purposely slip the clutch. After a few miles, no more slippage and has not slipped since for close to 10k miles. Clutch replacement is on the agenda , but for now its doing fine. Hope this helps
tip for getting the o rings in around the push rod.. cut an aluminum arrow shaft to around 6" and it will go over the PR and push evenly on the Orings (1 at a time) to pass into the channel. might help to blunt the end of the arrow shaft..
This is a question for those that have had their clutches done. Is there any chance you'll wash the grease or librication from the thrust washer?
Anything that might lose it lubricious or such to worry about? Never had the trans off. Keep thinking there's an input shaft bronze bushing in there someplace.
Clean the belhousing with brake cleaner and then use a long piece of duct tape to seal her up. She'll hold a entire bottle of mineral spirits, it will probably blow out the timing hole so be careful where you do it. But if she's working fine I doubt you need to clean it again.
If I was you, I would take that swing arm off again, swap out the conical push rod seals and replace with 6 o-rings (McMaster Carr part #93125k19 http://www.mcmaster.com/#93125k19, here is the WG post I found the McMaster Carr part number from http://wildguzzi.com/forum/index.php?topic=72742.0). Never know when those conical seals are going to give out. I know that it will be a PITA to take the swing arm off again, but it's much better than crabbin the frame Also, if you'd rather not buy the o-rings, shoot me a PM, I'll send some your way.
Ride it and pay attention to the clutch performance. You can wash/clean again later.