8-plate billet XS650 clutch project

[inxs]

- my billet body arrived today-its light...here are some pics with the high ratio primary gears i have for it...new set of plates on the way - just some machining to do...wifes going to hamburg over new year, hopefully she takes the apprentice with her

[Travis]

Here's the intro to this project from the clutch thread if you missed it.

Originally Posted by inxs

- here is a clutch modification done by fellow xsler peter von sphinx feat. herbert claeren...he is running a long-stroke 880ccm motor...this is designed to deal with the xstra loads of high performance motors and sidecars

- my winter get away will be to create one similar with a billet basket im waiting for-strong, doesnt get the chattering wear...the process will be the same, the xsact ammount removed will depend on the dimensions of the parts used...i will also be fixing a high ratio primary drive gear-4 teeth less-to the basket and the opposing-4 teeth more-gear to the crank

- this should be possible for all clutch variants but careful measurement first is cheap insurance

- i will combine this with an hydraulic clutch operator

- 8 friction plates @ 3.0mm...24.0mm

- 7 steel plates @ 1.4mm...9.8mm

- 33.8mm...original 7-6...29.4mm......4.4mm difference

- this is the xstra ammount of space required inside the mechanism
- also need to allow about 2.5mm for separation

- 4.4mm gained from turning approx 2.0mm from the inside surface of the boss and approx 2.5mm from the inside surface of the pressure plate
- 2.5mm gained by removing 1.5mm from the bottom of the boss and1.0mm from the outside of the pressure plate
- removing the 2.5mm from the boss underside requires filing the friction plate dog spaces in the basket
- use the pressure plate with the teeth and make sure that the teeth locate into the boss splines at all times


...2.0mm removed

...side view

...1.5mm from the bottom

...file to fit

...so

...2.5mm thinner

...1.0mm for clearance

...complete

...XJ900 springs

[Travis]

Originally Posted by inxs

Damn that clutch basket looks nice! I love machined billet things, especially when it's milled and you see the spirals from the tooling. Looking forward to seeing it all come together!

[mule]

Originally Posted by inxs

- my billet body arrived today-its light...here are some pics with the high ratio primary gears i have for it...new set of plates on the way - just some machining to do...wifes going to hamburg over new year, hopefully she takes the apprentice with her

So where do these parts come from??????

[inxs]

- the high ratio primary gears were originally produced by tony hall of halco in britain...he lost the fight against depression and halco doesnt exist anymore...

- however ivan hoey in australia has started producing them-this set is from his original batch - i know he had a second batch made but am not sure if there are any left ... his rephased 840cc has legs

ltr.management@bigpond.com

- the billet body was the last one made here in germany by a retired racing engineer who works out of his garage, this one was found in the far rear corner dust in a box behind a pallet after telling me at the XS 40th birthday celebration last may that he thought he still had 1 somewhere...maybe he will make more if pushed or rather, sweetened...i now have 2, after finding 1 inside a motor bought real cheap, and plan using it in a rephased 750 motor i have lying around-and no, theyre not for sale

[KevC]

- the high ratio primary gears were originally produced by tony hall of halco in britain...he lost the fight against depression and halco doesnt exist anymore...

A sad day for UK XS owners

.i now have 2, after finding 1 inside a motor bought real cheap, and plan using it in a rephased 750 motor i have lying around-and no, theyre not for sale

Now that is just plain greedy

Great project inxs

[inxs]

...or from twins-inn, germany...billet body and original primary with new springs exchanged for your original clutch body and primary gear...292 euro...its not exactly the same



twins-inn.de

- wolfgang speaks english but is difficult to get on the phone...email works best webmaster@Twins-Inn.de
- according to clarry the one i have is made for the 8 plate clutch-this one shown here is a billet replacement for the original...i dont know anyone who is using this but i have had it in my hands and inspected it, the finishing quality is not quite as good imho

[Travis]

Very nice... For the non-multilingual people (myself included) you should download google toolbar for your browser if you don't have it already. Whenever you go to page that is not in your language, it there is a button to translate the page. It does a pretty good job too.

[bill]

if someone will send me drawings and or instructions i will machine them up

[inxs]

- bill, there are 3 main different clutches for the XS, all a little different, the process is described as above, however the exact measurements will depend on the clutch...mine is the 7 plate clutch modified to 8 plate as above, hein has modified the later 6 plate clutch-the one with the wire holding the 'cushion' plates in...to date i dont know whether anyone has tried to modify the earlier 6 plate clutch
- the important things to remember are not to increase the overall size of the pack, and, the pressure plate notches must always remain in the boss splines, especially when the clutch is disengaged

[XSLeo]

I think the different primary gears are a great idea. It would make the transmission gears more usable. With my 17-32 sprockets I can putt along at 30 mph in high gear. Almost like an automatic transmission above 30 mph.
With the new primary this would be much harder. would need 2nd or 3rd to do this. and give a much lower rpm at 60 mph.