Who do we like for clutch kits?

Downeaster · Apr 17, 2019

Getting closer to getting the Zook ready to go. Blasted up and down the driveway a few times today, little surprised it didn't want to lift the front wheel. Assumed it was wheelspin.

Just for gits and shiggles, toddled over to the paved parking lot across the street and nailed the throttle. Aha...clutch is slipping. Notice the lever was all the way out at the end of the travel but some people like it that way so didn't think much of it. Adjusted what little adjustment was left, still slipping under hard throttle.

Sooooooooooo, in addition to everything else, it needs a clutch. I'm thinking springs, fibers and steels will get 'er done. I'm seeing some kits in the $50-$80 range and some others with the super techie carbon fiber and unobtainium components for North of $400! GAS-puh!

Don't need that, won't be pushing it that hard. Stock or a little stiffer is fine. Who do we like? I know Barnett used to be a big name.

5twins · Apr 17, 2019

It may not need a whole clutch, maybe just springs. I'd start with them. Pretty much every wet clutched Jap bike I've ever owned needed them.

SEd27 · Apr 17, 2019

I’ve got approx. 500km on a set of Barnett springs and really like them. My friction and steel plates were within spec. so I left them in.

At first I was worried that the new springs would be too stiff, but that quickly subsided once I got riding.

I also installed the Mikesxs/ Xs650 Direct upgraded needle bearing, Allen head bolt kit, and long clutch rod while I had everything opened up.

Downeaster · Apr 20, 2019

I think it's safe to say the clutch was toast...

All the steels have distinct ridges on them and as you can see the first fiber and the pressure plate are completely shot. Haven't looked up what a pressure plate is gonna cost me, but I'm sure it ain't gonna be cheap.

Entirely my fault for not spending more time evaluating the bike before I plunked down the cash, but I should have gotten a reach-around or at least a kiss for that kind of money...

EDIT: $40 for the pressure disk. I was expecting a three digit number at least.

gggGary · Apr 20, 2019

Yeah us street bikers forget how SERIOUSLY beat dirt bikes can be Road riders are pikers compared to the off roaders.
Sorry we haven't commented but clutch stuff is kinda bike specific what works great on model A might be a complete failure on model B
Maybe watch for a complete used clutch pack?

Downeaster · Apr 20, 2019

I got a rebuild kit from the dealer at a pretty reasonable price. All new steels, fibers and springs. Just added a pressure disk and an oil filter to the order. Main basket looks good.

Downeaster · Apr 20, 2019

gggGary said:
Yeah us street bikers forget how SERIOUSLY beat dirt bikes can be Road riders are pikers compared to the off roaders.
Sorry we haven't commented but clutch stuff is kinda bike specific what works great on model A might be a complete failure on model B
Maybe watch for a complete used clutch pack?

No problem on the lack of replies. Just because I don't let my lack of knowledge keep me from having an opinion doesn't mean everybody should!

GLJ · Apr 20, 2019

A good engine flush or 2 may be in order. All that missing fiber went somewhere. Amazing it even moved the bike.

Downeaster · Apr 20, 2019

GLJ said:
A good engine flush or 2 may be in order. All that missing fiber went somewhere. Amazing it even moved the bike.

Indeed. I'm more concerned about the 'luminum missing off both the pressure disk and the first fiber. Drained the oil and it was black as tar. No noticeable chunks thank goodness.

Open to suggestions about flushing procedure. Thinking maybe one rinse with mineral spirits or kerosene for starters. Good idea or no?

GLJ · Apr 20, 2019

Kerosene flush wouldn't hurt. I think then I would put in a cheap lightweight oil some snake oil of your preference, warm it up, maybe ride it easily for a mile or 2 and drain. Depending on what came out may do it again or just refill with oil that you plan on using. Then put 50 or so miles on it and change oil. Not familiar with with that engine does it have a cleanable oil filter?

Downeaster · Apr 20, 2019

Oil filter is a paper cartridge type. Probably a good idea to grab a few tho.

Grimly · Apr 20, 2019

I just fitted an EBC kit to my GS850, along with three new standard springs and three heavier ones. The clutch feels just right, now. Certainly a touch heavier than before but nowhere near as heavy as I recall the other GS felt with six HD springs.
Oh yes, reminds me - regarding flushing the engine - I dropped the sump plate and found the oil pickup strainer was 80% blocked with fibrous sludge from the old plates over the years. I couldn't get the screws out that retained the screen, so aimed a jet of brake cleaner at the muck and thankfully, it all washed out and down into the catch can underneath.
Just as well I decided to look, really.

Downeaster · Apr 22, 2019

The results of a douche with diesel. Black and nasty, but...

No major chunks. A couple of flakes of aluminum, but generally clean. The filter also showed some aluminum flaking, much like a worn chain guide on an XS. When I get the clutch parts in, I'll put a fresh filter and some cheap oil in it, run it for a bit and then change oil and filter again. I've got a 5 pack of filters coming from Amazon.

Downeaster · Apr 24, 2019

DAMMIT!

Normally, I love Amazon. Has everything, reasonable prices, fast shipping.

Apparently, they've either gone downhill, or have no f**king idea what a Suzuki DR-Z400 is. I've ordered 4 parts and 3 of them have been wrong, 2 of them not even close. Pictures on the website look good, description looks good, specifically mentions fitment for my bike, but what I get is something else entirely. This time it's the oil filters. Not within a country mile of being right.

I guess I'm going to have to put up with the dealer's glacial shipping times.

Superjet · Apr 24, 2019

I have to agree with you DE. I have found with Amazon that you need to do a bit more research. Seems they get the part numbers and fitment all mixed up. I double check the part number directly on the manufacturer website. Almost got caught on a few purchases, but now just do a little more searching to confirm parts.

Mailman · Apr 24, 2019

I have installed two sets of fiber plates and springs made by EBC and been very happy with the price and quality. eBay had the best prices.

Downeaster · Apr 24, 2019

The kit I got through the dealer is an EBC. Seems fine, waiting on a new pressure disk.

XSLeo · Apr 24, 2019

When I put in plates on my 75 I used Ferodo fibers. The steels I just cleaned up with sandpaper to remove the dark areas and rough them up a bit.
Did a few other thing to cleanup the rough spots, 70 lb springs. Works very well. With a fresh lubed cable and worm, pulls with two fingers.
Leo

Downeaster · Apr 24, 2019

This was the worst clutch I've ever gotten into. Even the steels were worn thin and had noticeable ridges on the outer edge. No way no how to save anything on this unit. Springs maybe, but the kit came with new springs so why take the chance.

Cable SEEMS okay, but that may change with the new clutch. In fact, based on this bike's appetite for money so far, I'd bet on it... :redface:

Some good news tho: NAPA had the filter for around the same price as the OEM. I'd liked to have had 2 or 3 cheapies to do multiple oil changes, but it is what it is.

GLJ · Apr 24, 2019

Downeaster said:
In fact, based on this bike's appetite for money so far, I'd bet on it...

You should have bought a 650 and turned it into a dual sport. May have been cheaper.

Who do we like for clutch kits?

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