Finished my clutch mod

[1tinindian]

My clutch has been slipping for a while now, and it came time to do something about it.

Thanks to all the great advice on this subject, I removed the rear narrow fiber plate and the fine wire spring and replaced them with a 7th wide plate, as well as a new Yamaha diaphragm spring.

No worries, I studied the clutch files until I could do this with my eyes closed, and I followed it to a "T"!

During dis-assembly, the fiber and friction plates all measured well within spec, with no discoloration nor warp age

The old clutch spring free height measured between 5.95-6.01mm, where the new spring measured between 6.30-6.50mm.

I took it out around 12am for some midnight Kookaloo, (I'm sure my neighbors just loved this!) and I'm very pleased with the results so far.
Tomorrow will get a better feel for how well its improved.

Question...I now feel the clutch lever engages farther away from the grip, is this the normal position, or am I in need of an adjustment?

Thanks to Randy (RPM) for the parts I needed and his usual fast shipping service.
I truly would be lost without this great resource of a forum and all its members.
My thanks also go out to Marsh for everything he does to keep us all together and sharing in all things FJ related.

Leon

[andyb]

Question...I now feel the clutch lever engages farther away from the grip, is this the normal position, or am I in need of an adjustment?

It's more where it's supposed to be.  You changed the stack height, which moved the point of engagement.  Ideally, you'd use a different master with adjustability in the lever to bring it back to where you're more comfortable.

[1tinindian]

Question...I now feel the clutch lever engages farther away from the grip, is this the normal position, or am I in need of an adjustment?

It's more where it's supposed to be.  You changed the stack height, which moved the point of engagement.  Ideally, you'd use a different master with adjustability in the lever to bring it back to where you're more comfortable.

OK, that sounds right.

One final question...
I'm aware of the adjustable levers, (have one for the front brake, and love it!), so can you tell me which clutch master will work without changing the hose to the slave cylinder.

The reason I ask, is because I have a new braided S/S line that is made for a stock FJ, and I would like to use it, AND, still be able to get the adjustable lever.

I'm thinking, maybe, one from an FJR??

Thanks,
Leon

[Mark Olson]

FJR 1300 is the ticket. adj lever and smooth operation.

[1tinindian]

FJR 1300 is the ticket. adj lever and smooth operation.

Just to confirm, you're saying this WILL use the stock FJ line to the slave cylinder?

Sorry, just want to be sure before buying one, and to avoid the problem to find out that it doesn't!

Thanks again guys!

Leon

[1tinindian]

OK, I took the FJ out for some hot laps around the countryside and WOW!
What a difference a non slipping clutch can make to an already awesome bike.
I was afraid I had been missing out on the full potential of this machine, and I was right, what a freakin freight train this thing is now!

Mark this day, 10-8-2011, as my first day of feeling the kookaloo!
Is it Rally time yet? LOL!

Take care guys and enjoy the rest of the riding season!

Leon

[Mark Olson]

FJR 1300 is the ticket. adj lever and smooth operation.

Just to confirm, you're saying this WILL use the stock FJ line to the slave cylinder?

Sorry, just want to be sure before buying one, and to avoid the problem to find out that it doesn't!

Thanks again guys!

Leon

yes , yes , yes, it fits with no problem.

[1tinindian]

Thank you Mark!

[Mark Olson]

your welcome 

[1tinindian]

I just bought one off of ebay, I should have it shortly!
Maybe I should look into doubling up the clutch spring for good measure!

Leon

[Alf]

I just bought one off of ebay, I should have it shortly!
Maybe I should look into doubling up the clutch spring for good measure!

Leon

don´t do it unless you have a powerful werewolf wrist!. When I fit mine I got a wrist injury in 1 week

[terryk]

I have a new spring doubled up with the old spring. The pull is acceptable although you need some care in engagement to be smooth, a little more than normal.

On the other hand, no clutch slip.

I replaced the entire clutch pack with a single new spring, went for a ride, burned the clutch friction plates and new metal plates to a crisp in 250 miles.

The shop fixed this under warranty as I suggested they double up on the spring and they suggested a single spring is OK.

Anyway, purchased this bike with 22K miles and I do not know if it is modified although I doubt it as it still has the original factory exhaust and all otherparts look stock. Still, pretty savage on the clutch.

Good luck.

[Mark Olson]

Ride it for a while with the extra disc and the single spring and let me know how it is .

I have the same set up but with a doubled up spring and at the end of a long riding day with lots of shifting and clutching my hand is shit.

It is funny to watch me at a stop and go when my hand is tired.

If I can take the extra spring out I would be much happier.

[FeralJuggernaut]

I did the double spring plates on the stock clutch master.  Don't sign up for any parade duties!   Then updated to an '03 FJR clutch master, back to 'normal' and I get the adjustable lever as a bonus!