GIF:
Cold start with the dry clutch conversion completed, I hesitate to say completed because I haven't taken it out for a shakedown ride yet. Once I have some flogging and heat cycles in her I'll be more confident. I used a KBike brand slipper clutch kit, not their conversion kit. On the 800cc wetclutch engines the drive shaft is shorter so I had a nut made by a friend machinist and milled the clutch drum down 6mm so I could get good engagement on the threaded driveshaft. There are a few minor variables I played with to get enough engagement on the big clutch nut and driveshaft.
1. Changed the shim behind the primary from 5mm to 4mm. Using 2x 2mm shims (McMaster-Carr is awesome)
2. Due to above I pushed the large clutch seal on the primary deeper so the clutch basket wouldn't rub.
There are two main concerns with my method of dry clutch conversion:
1. Choked the oil regulator on the main drive shaft where the push-rod resides
2. I used the wet clutch pushrod end as it had a longer collar and will hoepfully keep the needle bearing I inserted into the driveshaft seated for support.
3. Due to #2, I sunk and O ring into the shaft to help center the rod and keep the needle bearings from sliding more then necessary.
4. Longer pushrod is needed, but I used the end of another as a shim, much like some of the clutch slaves come with. THis gave me the proper length and utilized the wet clutch pushrod cap.
Some pics:
Operating table
Disassembly
Discovered wet clutch springs were shattered
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Primary gears from 916/749
Didn't actually need to replace the oil pump (ProTIP, if you pull an oil pump refill through the oil pressure switch hole)
Black eye and busted face from the primary gear puller launching unexpectedly 6" off the bike!
removed primaries, notice I left the original wet clutch shim on the shaft, i want maximum oil splash on the bearings, another reason i used smaller OD shims.
2x 2mm shims to space the primaryinbord by 1mm
engagement moving the drive gear inboard 1mm
Mock up, you can see only about 2mm of threads, no gonna work
Making the nut, don't ask for a price, my friend made it on barter.
Clutch machine work, 6mm bore on the drum and 6mm extention nut
dry fit
Powder coated old school clutch cover
second dry fit
All buttoned up, pay no attention to the extra long bolts, I have cut them down since
If I think of anything else I'll add it to this thread.
