New clutch

[mark1969]

Thought it seemed right to start a new thread - here's a link to the old one where I mentioned my clutch 'aspirations'. http://www.fjowners.com/index.php?topic=12827.msg136784#msg136784

I am going back to a single spring (new FJR one) and have purchased new clutch steels, fibres + the RPM shift kit. I have also decided to go back to the old master cylinder and so having sourced one and thoroughly cleaned / fitted new seals I will be fitting that too. The reason being I want an original clutch from lever to engagement. I'm getting tired of bleeding the ZZR M/C and want the chance to experience an original clutch as far as possible. I remember riding my old FJ's with original equipment and don't have any bad memories of slippage or bleeding issues..

While in purchase mode I also sourced a new (old stock) pushrod and because the slave cylinder was changed last year too, this really will be as far as possible an original clutch. All that said, I do have a braided clutch hose already fitted, but maybe that's one upgrade I'm willing to compromise on..!

Also, for the record, I'm not against upgrades / mods as I have a fair few, but all this stems back to having constant issues with the clutch which is after all a fundamental part of riding, and I want to be happy with it and not have to think about it through poor feel of the clutch lever or indeed slippage which is why I put the double spring in a while back...

One thing I've never found a definitive answer about is whether the FJR diaphragm spring is uprated compared to the FJ/XJR one. There is a lot of hearsay that it might be, but it is certainly cheaper compared to the FJ one over here in the UK. Either way, it's new, and that's the point for me.

So after all this waffle I have to fit my new parts which I hope to do in the next few days, and will update this thread for anyone interested.

Cheers

mark  

[FJmonkey]

I recommend you have a magnet on a stick for the shift kit upgrade. Something like this one:

I had to fish the bolt out of the sump a few times and would be SOL without it. Or you could plug hole the hole, but don't forget to remove the plug...

[FJ1100mjk]

^^^ A tool, that no toolbox should be without. Owned one for decades, and it has bailed me out a few times after one of those "oh shit, where did it go?" or similar episodes.

[theLeopard]

The bike works great on stock parts!
Upgrade for function (mechanical failure, driving demands) is my motto.

Ps, Randy, I really want one of those new rear suspension springs but i need intake boots & a chain first.

[Harvy]

One thing I've never found a definitive answer about is whether the FJR diaphragm spring is uprated compared to the FJ/XJR one. There is a lot of hearsay that it might be, but it is certainly cheaper compared to the FJ one over here in the UK. Either way, it's new, and that's the point for me.

Cheers

mark  

Mark, Randy (RPM) posted the relevant info about FJ vs FJR clamping force etc a few years back. If I can find it I will post up the msg number.
Or search for it yourself....... he included a few pictures for illustration of any differences he found.
Sounds like the only thing you are not replacing in the clutch department is the basket with attendant bearings.
Cheers
Harvy

[Mark Olson]

Mark 1969 ,

The clutch in stock form will most likely be fine for your riding style . Hang onto your upgrade parts just in case.

The clutch slip most common for the Fj is in the high rpm shifts under load at maximum acceleration.

If you keep the load light and stay away from 8k shifts you will be fine.

[mark1969]

Cheers guys, I will hang onto the parts and yes I have one of those telescopic magnets. Got me out of a mess a few years ago when I dropped the valve tool bolt into the engine on my old FJ...20 seconds of fishing and it was out.

Just got to pick up the clutch holding tool from post office tomorrow and away we go with the work on this one. Once fitted I'll take it easy on the new clutch for a few hundred miles anyway just to give it chance to bed in and then we'll see how it goes.

[mark1969]

After 3.5 hours of tinkering, I have the RPM shift kit and all the new clutch fibres/steels, shift shaft seals/circlip, pushrod and original master cylinder fitted.

All appears well, the bite point is much much better, the gears all change correctly (and smoothly) and I'm hopeful that it will be a better riding experience.

I didn't get chance to road test today, but will do so over the weekend...

Already just by starting up and testing it on the centre stand through the gears I'm keen to get out there and see how it all feels on the road.

The only downer was a large-ish puddle of oil on the garage floor which I am fairly sure came pouring out of the open shift shaft hole when I had the bike on the side stand...lesson learned!

It meant I had to use my last 500ml of VR1 to top up when all back together.

Will update when a thorough road test has been carried out.

Quick question, would people recommend I take it easy on the new clutch for a while. Is that accepted 'good practice' or does it not really matter?

[FJ_Hooligan]

Did you pre-soak the fibers in oil before installation?

[mark1969]

..

[mark1969]

Did you pre-soak the fibers in oil before installation?

Yes I soaked them overnight.

[FJ_Hooligan]

Ride it like you stole it.  :-)

[FJmonkey]

The only downer was a large-ish puddle of oil on the garage floor which I am fairly sure came pouring out of the open shift shaft hole when I had the bike on the side stand...lesson learned!

It meant I had to use my last 500ml of VR1 to top up when all back together.

Quick question, would people recommend I take it easy on the new clutch for a while. Is that accepted 'good practice' or does it not really matter?

You should not have lost any oil, you took something out you did not need to... But its done now and you will not need to crack it open for some time now. When I put in new steels and fibers I noticed the clutch had a slight shudder feel. It went away after about 500 miles or so. Ride normally or ride it like you stole it, the OEM clutch is good to go.

[Pat Conlon]

Did you take that wire out?

[copper]

If he had it on the side stand when he removed the shift rod to install the detent kit oil would have leaked out. Made the same mistake when I installed mine.