Clutch Time

[Nick_Ninja]

After 59,500 miles stick a fork in it -------- it is done (toast).

http://i3.photobucket.com/albums/y57/Nick_Ninja/ZZRClutch004.jpg

http://i3.photobucket.com/albums/y57/Nick_Ninja/ZZRClutch001.jpg

http://i3.photobucket.com/albums/y57/Nick_Ninja/ZZRClutch002.jpg

More pix to follow.:siesta:

[~Barn~]

I don't even know what I'm looking at.... Is that maple syrup? Cause like... you can't label it "Maple", unless it's actually from a particular tree, I don't think.
:dunno:

[Nick_Ninja]

I don't even know what I'm looking at.... Is that maple syrup? Cause like... you can't label it "Maple", unless it's actually from a particular tree, I don't think.
:dunno:

It's nectar of the engine gods:

http://www.silkoleneoil.com/images/silklogo.jpg

And those are friction plates soaking in it.

[pilot]

What was the first clue it gave you that it was going out?

Also, pix of the tear down and any concerns along the way would be great.

Fellow ZZR rider,
pilot

[Nick_Ninja]

The first clue was while wrapping the engine up around 7K RPM and shifting through the last two highest gears the clutch would not engage. It took a couple of seconds of throttle prior to connecting. As far as the tear down it's quite simple. Remove the three oil plugs --- drain the oil. Remove the twelve clutch cover bolts and use the three pry points provided at various points around the circumference of the clutch cover. Whala ---- access to the internals.

I used a basic Teflon pancake spatula to scrape the residual gasket off the contact surface and then took some 0000 steel wool to remove some stubborn areas.

There is more --- but I haven't loaded those pix's yet. :D

[Nick_Ninja]

Keeping track of the twelve clutch cover bolts isn't too taxing. Take the new gasket and trace the outline on the provided paper insert. Punch holes in the marked locations and insert the bolts in the corresponding locations. So simple a Cave Man could do it :D

http://i3.photobucket.com/albums/y57/Nick_Ninja/ZZRClutch.jpg

[King Nothing]

ooga ogga. me no fix cluch.

[Dr. Joe Siphek]

that's alot of miles on a stock clutch, i'm curious as how you did it.

Just for giggles, how often do you dry shift up or down? Or do you pull the clutch in for everything?

[rforsythe]

You can get many, many miles from a clutch if you aren't ripping wheelies, using it to hold you up on hills, feathering it, or launching hard on starts. In other words don't abuse it, and save the big throttle grabs for when the lever is fully released. Also keep the spring pull adjusted properly so it engages 100%.

[Nick_Ninja]

that's alot of miles on a stock clutch, i'm curious as how you did it.

Just for giggles, how often do you dry shift up or down? Or do you pull the clutch in for everything?

The clutch has been engaged for EVERY shift :D

[Devaclis]

I changed mine after over 100k miles. Did not even need a new gasket :)

Jeff, have any libatory assistance with that install?

[Nick_Ninja]

I changed mine after over 100k miles. Did not even need a new gasket :)

Jeff, have any libatory assistance with that install?

No comment.

[Devaclis]

Can you shoot a close-up of the old plates and steel's? Did you just replace the plates? How about springs?

[pilot]

http://content.answers.com/main/content/wp/en/6/62/MartyFeldman.jpg

[Nick_Ninja]

Can you shoot a close-up of the old plates and steel's? Did you just replace the plates? How about springs?

Yeah, I am replaceing the whole deal. I'll snap pix soon.

BTW --- I hate Marty Feldman :down:

[dm_gsxr]

I have 61k on the 'busa and it all seems ok. I've engaged the clutch for each shift :)

I did note last year that I found a hidden 5.5 th gear neutral and have found it a couple of more times since then. Could that indicate an upcoming issue with the clutch?

Thanks for the notes. I'm definitely paying attention :)

Carl

Edit: added "neutral"

[Nick_Ninja]

Yep. I was hitting a few false positive neutrals prior to the aforementioned slipping.

[Nick_Ninja]

And the final steps:

Clutch Hub housing

http://i3.photobucket.com/albums/y57/Nick_Ninja/ZZRClutch011.jpg


http://i3.photobucket.com/albums/y57/Nick_Ninja/ZZRClutch012.jpg


Clutch Hub

http://i3.photobucket.com/albums/y57/Nick_Ninja/ZZRClutch013.jpg

Torque the Clutch hub nut

http://i3.photobucket.com/albums/y57/Nick_Ninja/ZZRClutch014.jpg


THE tool fo the job

http://i3.photobucket.com/albums/y57/Nick_Ninja/ZZRClutch024.jpg

[Nick_Ninja]

Clutch plates alternate friction / steel

http://i3.photobucket.com/albums/y57/Nick_Ninja/ZZRClutch015.jpg

http://i3.photobucket.com/albums/y57/Nick_Ninja/ZZRClutch017.jpg

Clutch springs (6)

http://i3.photobucket.com/albums/y57/Nick_Ninja/ZZRClutch021.jpg

Torque to spec

http://i3.photobucket.com/albums/y57/Nick_Ninja/ZZRClutch023.jpg


Replace the clutch cover gasket and cover. Fill with oil. Go ride :D