Ok I am exited about this so here goes.
My bike has had the clutch judder/rear wheel jump when releasing clutch and rattle at idle in clutch and harsh vibration on accel between 3000-4000rpm well I believe I have found the cause of all these.
I have been talking with my local dealer about these problems and reading about the tube nut coming loose so yesterday I went to work myself and removed the clutch basket to check the tube nut well as I went in all was looking good and the tube nut was found to be tight.
When I removed the clutch hub I noticed the the damper/torsion springs were so loose they had lost a lot of tention and were just flopping around in the holder.
I knew then I had found what causes all the problems as listed above I thought what will I do as my bike was purchased in Feb 07 and only had 14500km on the clock and is still in warranty.
I used a brass hammer and closed the retainer tabs as shown in the pic below to make the springs tight in there postion I know they have lost a lot of there lenght and that is something I have to talk to the dealer about.
I reassembled the clutch using loctite on the tube nut and finished the job.
Well I noticed the difference as soon as the bike started it ran so quite and today I went for a ride well this is a totally different bike there is no rattle in the clutch at idle or cruising along at any speed, The vibe/harshness when accel between 3000-4000rpm has totally gone the bike is so smooth right through the rev range it is a different bike.
What is happening the springs loose tention and they become so loose in the holder this is the rattle at idle and the harsh/vibe on accel is the springs are not inline and it puts the clutch hub out of balance and the judder/wheel hop when releasing the clutch is when the springs get short and loose tention in the hub it is a rebound affect in the clutch hub bouncing back and forward in the clutch hub this is the whole problem we are all having in the drive on our bikes
The springs in the clutch hub are to weak for the engine torque I will be talking with my local dealer next week don't know what he will say when I tell him I pulled the engine apart but this is the thing we have been all looking for
I hope suz have built a stronger clutch hub or better springs. I was so exited when I rode my bike today it has changed the shift feel between gears
If you want to check my theory just do a search for clutch damper springs or clutch torsion springs and read about there failure.
I took this pic from another thread and if you look closely at the metal tabs that hold the springs in look how much gape there is between the spring and the metal tab this is why the springs are rattling around
I have been reading on goggle about the damper/torsion springs and everything says if they break or loose tention they will cause judder and vibration here are a few that I found
Clutch chatters when engaging
Possible diagnosis Likely solution
Damper springs in the clutch disc hub or the marcel spring between the facings is fatigued Replace the clutch disc
Noise; clicking or rattling at idle RPM with the pedal released
weak spring(s) replace clutch hub