Fun With Digital Calipers and a Burned Out Clutch

While I'm waiting for a set of piston rings I decided to examine the clutch and kick starter. Lets just say I had a lot better luck with the kick start assembly than I did with the clutch.

The kick start assembly is fairly basic with the shaft, washer assembly, main gears, and return spring. There are some other parts in there that I wont go into detail about but luckily the previous owner did not disassemble the shaft assembly itself so reassembly was fairly simple.

The return spring sits approx half way on the shaft and needs to be "wound" during assembly. I found some material on an xs forum where someone used a zip tie to rotate the spring around and wind it up. I used the same method but substituted with a piece of rope.Installation was a breeze it took maybe 2 attempts and 20min of my time.

Disassembling the clutch wasn't something I wanted to do, but it was necessary to inspect the clutch plates and check for wear.

Upon inspection with my digital calipers I realized I'm outside the tolerance for operation. Have a look below:

The accepted tolerance for clutch plates are in the range of 3.5mm to 3.1mm only a 0.122 difference
 and my plates are averaging 2.85 (not good). Somebody was riding this clutch hard...