My Super Clutch Upgrade For Street or Racing

[ben2go]

Sounds like your bike as been taken care of.Not many have been.Plus you know how to properly use a clutch.Most new riders do not.A performance clutch won't help a new rider but once a newbie needs a new,here's the upgrade.

[burning1]

Don't let  my comments take anything away from this write-up; it's an excellent one with great pictures. Thanks for posting it up. 

[nydad19]

so what would be the signs that the steel clutch plates and pressure plate are going or bad.....what should i be looking for when i take it apart

[burning1]

On the pressure plates, look for excessive wear of the friction material. I don't recall the permitted minimum pad thickness, but I bet it's in the service manual. On the steel plates, look for excessive bluing, and excessive runout.

[ben2go]

so what would be the signs that the steel clutch plates and pressure plate are going or bad.....what should i be looking for when i take it apart

Bluing of the steel clutch plates is the first sign that they have been over heated.Also look at the pressure plate and check for scoring and bluing.The pressure plate is the plate that the springs are set in.Also check the warpage of the plates.To do this you will need a dead flat surface and a feeler gauge.I use a stone counter top.Clean the plates really well the some cleaner.Lay them flat on what ever surface you choose to check them on.Be sure NOT to press them down.Now try to slide a feeler gauge under any gaps.if a 0.10mm(0.004in.) or larger fits under it,it's to warped to use.Check both sides.The next is the thickness.Check it with a micrometer every inch.It should be no thinner than 2.62mm(0.103in).I got these measurement from my Clymer manual and it's the ones I used for my clutch job.There's nothing written on the pressure plate.It's one of those use your bestest judgement on it.

[nydad19]

whats the name of the gasket i need when i do this repair??...i shouldnt need the micrometer or feeler gauge if im changing the steel plates also right..

[ben2go]

Gasket,clutch is how it is stated on the Suzuki parts fiche.

[nydad19]

yea i went to bike bandit and the part number you gave matched up with the clutch gasket its on the way

[noiseguy]

Anyone here tried bead or sandblasting the steel plates to roughen them up? I've heard this gives you better clutch modulation (more like a dry clutch) but I've never had a chance to try it.

[ben2go]

Anyone here tried bead or sandblasting the steel plates to roughen them up? I've heard this gives you better clutch modulation (more like a dry clutch) but I've never had a chance to try it.

I have not because it removes to much material,that's why I stated that I use 600 grit sand paper.

[werase643]

I throw them on the ground(concrete) and scuff them up with my boot......seriously!
then flip them over and do the other side

endurance racing trick        fast and works

[nydad19]

so i did the whole clutch upgrade with a complete barnett clutch kit... ..everything went great besides the fact it took me longer to get the old gasket off then to actually replace the disks and springs.. .but anyway now i go to reap the benefits of my repair and the bike wont start for some reason... ..i got gas and everything else seems fine...any ideas on what might be going on

[ben2go]

so i did the whole clutch upgrade with a complete barnett clutch kit... ..everything went great besides the fact it took me longer to get the old gasket off then to actually replace the disks and springs.. .but anyway now i go to reap the benefits of my repair and the bike wont start for some reason... ..i got gas and everything else seems fine...any ideas on what might be going on

Replacing the clutch shouldn't cause starting issues.Did you get everything set up correctly in the ignition when you reinstalled it?Ignition rotor set and torqued properly?I added a small drop of blue loctite to the ignition rotor bolt.I've seen those back out and there's not much torque holding them on.Is the switch working on the clutch lever.Those can be a pain.Un plug the wires and connect them together to make sure it isn't the clutch lever switch.

[nydad19]

i got it started but it ran crazy and keeps cutting out on me...before i did this it ran fine so im guessing somethings up with ignition but i did everything right.....took off the screws and bolt and then the ground and put it back on when i was done..when i was taking off the the rotor it spun on me at first while i was holding it with a wrench could that have somethin to do with it...besides that everything went texbook

[ben2go]

i got it started but it ran crazy and keeps cutting out on me...before i did this it ran fine so im guessing somethings up with ignition but i did everything right.....took off the screws and bolt and then the ground and put it back on when i was done..when i was taking off the the rotor it spun on me at first while i was holding it with a wrench could that have somethin to do with it...besides that everything went texbook

I wouldn't think so.Did it line back up and seat into the slot properly?When I remove/install mine.I put my bike in first gear, and hold the brake pedal down with my knee, while I remove/install the ignition rotor bolt.Check for pinched or bare wires around the side cover where it goes through the cover.

[nydad19]

im sure nothing got pinched in the cover and the rotor sat properly when i tightened it up...im at a loss, im gonna have to go at the assembly tomorrow to double check everything...i cant imagine it being anything else it started and idled fine before.....would something going on in the assembly cause the problems im having though..rough idle,cutting out,and weird squeell sound when trying to start

[ben2go]

im sure nothing got pinched in the cover and the rotor sat properly when i tightened it up...im at a loss, im gonna have to go at the assembly tomorrow to double check everything...i cant imagine it being anything else it started and idled fine before.....would something going on in the assembly cause the problems im having though..rough idle,cutting out,and weird squeell sound when trying to start

Nothing in the clutch should be doing that.All I can think of is something in the ignition system.The only thing in the clutch system that controls the electric system is the switch under the clutch lever on the handle bars.It keeps the engine from starting until the clutch lever is pulled in.

[nydad19]

something must be going on with the ignition then....figures   

[nydad19]

i got the bike running and wow ...what a difference,i used all six springs and boy does this clutch grab now...it stopped slipping and the gears move great...thank you for the advice ben2go..this is definitely a great upgrade or repair in general...my first time ever doing this job and i must say it wasnt bad at all,definitely need a clymer and the right tools though..shouldn't take more then an hour or two depending on how bad the gasket is on there....i recommend for anyone having clutch issues or just want a better setup..cost me about $200 for the barnett clutch kit(springs ,friction plates,steel plates) the gasket, and the clymer manual

[ben2go]

i got the bike running and wow ...what a difference,i used all six springs and boy does this clutch grab now...it stopped slipping and the gears move great...thank you for the advice ben2go..this is definitely a great upgrade or repair in general...my first time ever doing this job and i must say it wasnt bad at all,definitely need a clymer and the right tools though..shouldn't take more then an hour or two depending on how bad the gasket is on there....i recommend for anyone having clutch issues or just want a better setup..cost me about $200 for the barnett clutch kit(springs ,friction plates,steel plates) the gasket, and the clymer manual

You're welcome and congrats on getting the bike running.hope this write up helps more people.