I talked to Barnett today. I think I'm going to order their frictions and springs.
He was pretty helpful, basically this problem is from the discs "slipping" then catching abrubtly at the last moment (instead of gradually catching). It is not from the plates sticking together from the oil however the slipping may be due to the oil. He said really when you havethe bike going, the oil is getting slung off so fast it is a non issue.
Further (and most helpful)..he mentioned glazing the plates will do this. which occurs anytime you hold the clutche in
these plates barely move apart so pulling the clutch in effectively allows the frictions to generate lots of heat and glaze over (by contrast if you shift in neutral and let go, they will spin together (not generating heat). So for those who are in constant stop and go and just hold the clutch in rather than shift to neutral...or those who idle in the morning by holding the clutch in (the worse thing you can do) this contributes to the problem.
He was doubtful of drilling holes in the clutch basket, he said he imagines the advantage is from putting new plates in all together.
For those who have it coming back, he mentioned its probably from your riding style where you pull/hold in the clutch either at lights etc...all the while glazing plates and getting the clutch to slip and catch again. After the bike warms up, the glaze isn't a problem, its when the plates are cool.
I think the reason i was getting positive results with holding the clutch in is also the downfall. I heat up the clutch (contributing to long term glaze) but it also helps prevent slipping since the discs heat up faster with friction.
I do not know if I am in total agreement with his assesment here. Everyone that has done the "Holes in the clutch hub fix" has reported the problems went away. This with many just re-installing the same clutch plates ....
I myself opted for the Kevlar clutch kit,( heavier springs, and the Kevlar friction plates) I did not replace the flat steel plates.
This cured the problem for almost a whole year...but it returned...to a lesser degree. (mostly only on real cold days or short warm ups) But went away within a 1/2 mile.
I would have to say my style of riding would not contribute to the glaziing effect....I shift quickly, and do not sit at lights holding the clutch in.
For the record, I replaced my clutch not because of the "coffee grinder" symptoms , but because I could feel the clutch slip at high speeds. Nothing more embarressing and possibly dangerous to pull out to pass a truck at 85 mph and feel the motor slip.
I would reccomend the Kevlar or any "heavy duty" clutch for the bike, along with stiffer springs, and I would suggest either wet sanding the non-friction metal plates with 220 grit or replacing them completely. A fellow Vulcaneer redid his clutch with the same kit I used but added this extra step, and said the coffee grinder never came back.
Oddly, this is the only bike I have ever owned that did this, so my thinking here is it is inheirit design issue with this bike. The "holes in the basket" fix was issued by Kawasaki...it was not something someone just made up.