Post by captain chaos on Jul 18, 2013 18:44:58 GMT
You will need
1. a piece of aluminium plate minimum size 180mm x 110mm x 10mm thick
2. GS750 clutch pusher part No 23121-45000
3. GS750 clutch push rod part No 23110-45001
4. GS750 push rod holder part No 23115-45000
5. GS750 push rod seal part No 09283-08001
6. bandit or gsxr clutch slave cylinder
7. bandit or gsxr clutch master cylinder
8. clutch hose
9. some 16mm to 20mm alluminium bar to make pillars from
I made the pusher and push rod my self, because I can.
The old and new parts
Some gearboxes are easy to modify others need stripping and have a machine shop bore out the shaft.
First remove the clutch cover, clutch pressure plate, sprocket cover and seal retainer (its just in front of the sprocket held by 2 M6 screws)
Look at the end of the mainshaft in the middle of the clutch, if it has a small countersink in the end its the difficult one, you will need to strip the motor. If it has a large countersink with a 11mm dia metal plug in it its easy.
At the sprocket end knock an old screwdriver into the middle of the rubber plug in front of the sprocket, you can then prise the plug out.
Using a long length of 6mm or 8mm bar down the middle of the mainshaft tap out the little metal plug from the clutch end.
Fit the GS750 push rod holder and seal in place of the rubber plug
From the clutch end fit the push rod and the pusher.
Remove the actuator and roller bearing from the pressure plate and fit the roller bearing to the pusher.
Re fit the pressure plate
Mark the positions of the fixing holes on the ally plate (I used the front two and the back one but you could make a bigger plate and use more fixings)
Drill these holes 6mm diameter then put some bolts through and loosley fit. you can then mark the centre of the push rod on the plate.
Cut a hole on this centre that the slave cylinder will fit snugly into. Then mark, drill and tap M6 for the slave cylinder mouting screws
You will need to make up some pillars to mount the plate on, the push rod needs some clearance (to allow for clutch plate wear) when the cylinder is fully retracted
Fit the master cylinder and hose, bleed the system and test
The slave cylinder on its mouting plate
From the back
1. a piece of aluminium plate minimum size 180mm x 110mm x 10mm thick
2. GS750 clutch pusher part No 23121-45000
3. GS750 clutch push rod part No 23110-45001
4. GS750 push rod holder part No 23115-45000
5. GS750 push rod seal part No 09283-08001
6. bandit or gsxr clutch slave cylinder
7. bandit or gsxr clutch master cylinder
8. clutch hose
9. some 16mm to 20mm alluminium bar to make pillars from
I made the pusher and push rod my self, because I can.
The old and new parts
Some gearboxes are easy to modify others need stripping and have a machine shop bore out the shaft.
First remove the clutch cover, clutch pressure plate, sprocket cover and seal retainer (its just in front of the sprocket held by 2 M6 screws)
Look at the end of the mainshaft in the middle of the clutch, if it has a small countersink in the end its the difficult one, you will need to strip the motor. If it has a large countersink with a 11mm dia metal plug in it its easy.
At the sprocket end knock an old screwdriver into the middle of the rubber plug in front of the sprocket, you can then prise the plug out.
Using a long length of 6mm or 8mm bar down the middle of the mainshaft tap out the little metal plug from the clutch end.
Fit the GS750 push rod holder and seal in place of the rubber plug
From the clutch end fit the push rod and the pusher.
Remove the actuator and roller bearing from the pressure plate and fit the roller bearing to the pusher.
Re fit the pressure plate
Mark the positions of the fixing holes on the ally plate (I used the front two and the back one but you could make a bigger plate and use more fixings)
Drill these holes 6mm diameter then put some bolts through and loosley fit. you can then mark the centre of the push rod on the plate.
Cut a hole on this centre that the slave cylinder will fit snugly into. Then mark, drill and tap M6 for the slave cylinder mouting screws
You will need to make up some pillars to mount the plate on, the push rod needs some clearance (to allow for clutch plate wear) when the cylinder is fully retracted
Fit the master cylinder and hose, bleed the system and test
The slave cylinder on its mouting plate
From the back