GS1000 hydraulic clutch

[salty_monk]

Good idea with the straw...

[tatu]

I have been looking on the net, for a single acting ram

http://www.mackcorp.com/featuredproductrelease/min_hiPressure.html

I remember seeing some pilot control rams but couldn't find it today.

http://news.thomasnet.com/fullstory/Hydraulic-Cylinders-for-use-in-workholding-applications-9469

Maybe these'll give you some ideas?

[Agemax]

cheers Tatu but i think i am good to go. i got a PDF from an old OSS thread (thanks Normand) and i have all the info i need. there is enough clearance for the pushrod next to the front sprocket and the link above with the straw will help with the exposed pushrod.

the only dilemma i have now is to find out what main shaft i have fitted. there are 2 types. one with just a "plug" in the end of the hollow shaft, which is easy, just knock the bugger out. or the 2nd is the solid shaft. which means stripping the motor and either replacing the mainshaft with the hollow one or getting my shaft machined.

i will find out tomorrow when i pull the clutch pressure plate off and have a look.
if it turns out to be the solid shaft then the whole project will be crumpled up,urinated on and thrown in the next door neighbours compost heap!

[Flatline_Racing]

I learned about this after having my transmission undercut and rebuilt. The shaft is unfortunatly solid. But I have a spare that is hollow so I will just have to swap everything over to the other shaft. It is easy to do, the hardest part is that one gear is pressed on.

[Agemax]

yayyyyyyy something has finally gone in my favour for once. i have the hollow mainshaft.

before....



after...



now i can go ahead and order up some parts.....

[Agemax]

right, after some more research i have found a slave cylinder from a GAS GAS motocross bike. it is a slim design which i am sure will fit between the crankcases and the sprocket/chain. the mounting flange is 27mm diameter so i will have to make a plate to mount it in the original 47mm hole left by removing the rubber transmission plug.
here are a few pics. (sorry for bad quality)









i will have to make up some sort of push rod "end" to mate with the slave piston. i have ordered a clutch "pusher", the part that fits into the pressure plate, from a 93 GSXR which will fit right in.

[Flatline_Racing]

What is the piston diameter of that beauty and how much travel does it have?

[Agemax]

What is the piston diameter of that beauty and how much travel does it have?

i am not sure, the flange O/D is 29mm so i will guess at 25mm piston diameter.
i have not actually bought it yet as i was waiting for some feedback from you guys to see what you think.

the travel only has to be 2mm but i am guessing most slaves will travel at least that much.
did you get the PDF?

[Flatline_Racing]

...did you get the PDF?

Yes I did. Thank you very much

[quexpress]

yayyyyyyy something has finally gone in my favour for once. i have the hollow mainshaft.

now i can go ahead and order up some parts.....

That's great Adrian!

[Agemax]

more progress today, the slave i was interested in on ebay spookily went up in price when the seller realised i was interested in it. i did ask him quite a few questions about size, width,height,flange diameter etc.....
so i looked around a bit more and found another from a 400 Gas Gas. this guy was only 10 miles up the road from me. the 400 slave is actually a smaller unit with a larger piston diameter, 29mm. it has a 4mm stroke which could be increased to 5mm with a bit of machining.(if needed).it also has 3 mounting holes compared to 2 on the other one.
lighter is for size comparison...



knocked up a spacer so it sits central in the crankcase hole and it looks pretty good. i will need to shave a bit off the crankcase casting to get it to sit vertical and the top mount hole will need to be machined down slightly to miss the chain and the hole counterbored for an allen bolt to fit in flush.
i need to make an adaptor plate to mount it now, using the 2 bolt holes that secured the rubber mainshaft end plug locking tab thingy.

without chain.....



and with...

[tatu]

I like the look of that, how will you machine the cranckase?

[Agemax]

the only bit that needs machining is on the left of the slave,where the mount hole is.
there is an extrusion on the crankcase that prevents the slave from rotating anti clockwise as far as it needs to go. it is not a lot and can be done with a dremmel with the motor in place.

[tatu]

You can move the holes about on the slave, just got your volumes to tune and you're away.

[Agemax]

You can move the holes about on the slave, just got your volumes to tune and you're away.

not sure i am with you on the holes....

i plan to use copper brake pipe from the slave up to a joint to a s/s braided hose under tank. that way i can use different diameter I/D copper pipe to get the pressure and the feel right on the lever