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GS1000 hydraulic clutch

fitted and working, very light clutch action. worth the time and effort. no more cable woes........

 
the difference between the 2 clutch covers now. still have to dress up a few edges and tidy the welds.(it was a bitch to weld) a massive weight saving of 370 grams........
 
Do you have a machine shop, lathe, etc. Adrian? That is very nice stuff!
 
quexpress said:
Do you have a machine shop, lathe, etc. Adrian? That is very nice stuff!
Click to expand...

i have access to a machine shop for important bits, my wife is ever so mean and wont let me put a lathe and a milling machine in the kitchen........:eek:

some rubbish excuse like "we wont have room for the cooker and washing machine". :-k
 
LOL! Searching to see if anybody made a ready-built solution for the 1100E, I found this: www.orientexpress.com/images/catalog/OER2010LowerEndClutch.pdf‎
On the last page:
CABLE CONVERSION KIT
Eliminates the standard hydraulic clutch cylinders and converts to a simple screw-type cable activated system for smooth clutch engagement. Available for Gen 1, Gen 2 GSX1300R in billet aluminum finish or black anodized.
Click to expand...
FWIW, the clutch on my Busa is a pain in the rear to bleed - harder to do than hydraulic brakes on a mountain bike.
 
Agemax said:
i have access to a machine shop for important bits, my wife is ever so mean and wont let me put a lathe and a milling machine in the kitchen........:eek:

some rubbish excuse like "we wont have room for the cooker and washing machine". :-k
Click to expand...
That is tough to accept! :p
 
Agemax said:
the difference between the 2 clutch covers now. still have to dress up a few edges and tidy the welds.(it was a bitch to weld) a massive weight saving of 370 grams........
Click to expand...


Adrian, The work your are doing is amazing to me. Curious though, what will the clutch cover be like when finished obviously can't have a large opening for operation? Thanks for keeping us lesser talented members involved. Ray
,
 
Ghostgs1 said:
Adrian, The work your are doing is amazing to me. Curious though, what will the clutch cover be like when finished obviously can't have a large opening for operation? Thanks for keeping us lesser talented members involved. Ray
,
Click to expand...

hi Ray, when finished it will look like this pic, but without all the webbing from the cover covering the clutch.



as it is hydraulic operation now, it is operated from the left side so there is no need for the strengthening webs and mechanism for clutch release in the cover.It has a clear acrylic cover over the opening to keep all the oil in......
 
here is a pic of the parts required for the modification.




1. slave cylinder.GasGas 400EC 2004
2. GSXR clutch pusher, with thrust bearing and washer(s).
3. pushrod. 8mm silver steel. carbon heat treated at each end.(not shown)
4. mounting plate, 5mm mild steel, cut and drilled to fit
5. nylon spacer. plugs the original hole in crankcases, and used as a pushrod support. 8mm oil seal fitted and 2 x 6mm tapped holes to assist in removing plug if required.

obviously you will need a clutch M/C and hydraulic hose.

NOTE; this mod will only fit with an offset front sprocket. original sprocket cover may fit with a few mods. i am not using it so i dont know, and i havent got one to try.
 
clutch as it looks now.......



modded clutch cover, just been vapor blasted, waiting for lexan window and oil sight glass, then paint.



nylon spacer fitted, with oil seal and pushrod located.



mounting plate fitted.....



finally, how the slave sits, not bolted on.


there is a lot more clearance between the slave and the chain, the pic is very deceptive..
 
The lower case on the GS1000 is essentially the same as the 1100/1150?

Not that I'm thinking of doing this. :)

Ok, I am thinking.... ;)
 
AJ said:
The lower case on the GS1000 is essentially the same as the 1100/1150?

Not that I'm thinking of doing this. :)

Ok, I am thinking.... ;)
Click to expand...

i could give the exact dimensions of everything if you plan on going ahead but i guess the pushrod length may be different with an 1100/1150 engine and i dont know if the clutch and countershaft is the same length and i/d, if indeed they have a hollow shaft.....
 
Your set up look great Adrian! Very well done!
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