SuzukiSavage.com - Beefing up the Clutch

ohiomoto Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2679 WTF is JOG?	Re: Beefing up the Clutch Reply #45 - 03/12/21 at 05:39:07 Cool stuff as always. We need a a sticky post where you can list and link all of these mods and the detailed information that you put in them.
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 17783 Camp Springs, Kentucky Gender:	Re: Beefing up the Clutch Reply #46 - 03/12/21 at 07:16:59 DragBikeMike: Great job finding, fitting and finagling the stuff together! Mike's modified clutch is definitely a beneficial improvement when you have a significant increase in HP
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TheSneeze Serious Thumper Offline Posts: 1201 Northern Nevada Gender:	Re: Beefing up the Clutch Reply #47 - 12/02/21 at 09:09:08 Based on your numbers, you lowered the spring seats 1mm? Installed height went from 24.4mm to 25.4mm.
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DragBikeMike

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Re: Beefing up the Clutch
Reply #48 - 12/02/21 at 15:56:24

Yes Sneezy, I ended up with an installed height of 25.4. I would have preferred 26mm, but there just isn't enough meat on the release plate to allow cutting it back that far.

So, I have 0.6mm more spring preload than stock. It's working fine. Still zero slippage after a whole bunch of miles. It's been thoroughly tested. It handles everything from the box-stock motor all the way up to the full 97mm flat-top piston with all the trimmings. The only problem I have encountered is an occasional squeal. That only happens when I try to start off with heavy throttle and cold oil, or when I screw up and try to start off from a dead stop in 3rd or 4th gear (it's an old age thing).

The buggah takes a lickin and keeps on tickin.

It should be noted that I don't dump the clutch, burn rubber, or power shift, but it definitely sees more than it's fair share of WOT.

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TheSneeze

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Re: Beefing up the Clutch
Reply #49 - 12/02/21 at 16:03:41

I plan on having a local machine shop cut the spring seats for me, since my wife doesn't like the price tag on a Bridgeport knee mill let alone a bench lathe for the round bits. I keep my eyes on all the estate sales in my area just in case I run across a steal. Same shop will cut the side cover for the longer starter gear shaft. Support your local businesses! Cool

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Every twenty minute job is a stripped thread away from being a three day ordeal.

'87 LS650h Savage Street Tracker
'86 LS650g Savage (parts bike)
'81 Kawasaki KZ750e ELR tribute

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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 17783 Camp Springs, Kentucky Gender:	Re: Beefing up the Clutch Reply #50 - 01/09/22 at 16:24:58 I had some time today to work on this clutch improvement. To make the hole in in the clutch basket larger.....I used my lathe and a 1-3/4" (44mm) holes saw.
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 17783 Camp Springs, Kentucky Gender:	Re: Beefing up the Clutch Reply #51 - 01/09/22 at 16:25:40 The hole saw did a wonderful job....it cut through the aluminum easily and made a nice tidy hole.
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 17783 Camp Springs, Kentucky Gender:	Re: Beefing up the Clutch Reply #52 - 01/09/22 at 16:26:15 The hole was exactly the size it needed to be!
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 17783 Camp Springs, Kentucky Gender:	Re: Beefing up the Clutch Reply #53 - 01/09/22 at 16:28:00 I then used a Forstner bit in my milling machine to cut the spring pockets a bit deeper. I had made a fixture to hold the piece and allow me to rotate it to cut all 4 pockets.
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 17783 Camp Springs, Kentucky Gender:	Re: Beefing up the Clutch Reply #54 - 01/09/22 at 16:28:37 The Forstner bit cut the aluminum like it was butter!
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TheSneeze Serious Thumper Offline Posts: 1201 Northern Nevada Gender:	Re: Beefing up the Clutch Reply #55 - 01/09/22 at 16:32:01 Finding the perfect size HOLE SAW is mind boggling! Those seem to wobble more than desired making the hole too large (or larger than the listed size). I guess when you have a lathe and can true it up properly. Man, I wish I had a lathe!
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Dave

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Re: Beefing up the Clutch
Reply #56 - 01/09/22 at 16:32:50

My lathe and milling machine made this work really easy - but I do believe you could do both of these on a drill press if you have a hole saw and the correct size Forstner bit.

DragBikeMike did an amazing job of figuring this out. The amazing thing is how well this all goes together. Before I took my clutch apart I measured the distance the push rod stuck out, and it was 12.4mm. I then installed the DR650 inner clutch basket, replaced the outer disc with a new one that is the same ID as all the others, then added another steel and fiber disc....and when I got it put together and checked my push rod length - it was 12.4mm!

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TheSneeze Serious Thumper Offline Posts: 1201 Northern Nevada Gender:	Re: Beefing up the Clutch Reply #57 - 01/09/22 at 16:34:02 Yeah, I want a knee mill too....
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DragBikeMike Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 4121 Honolulu	Re: Beefing up the Clutch Reply #58 - 01/10/22 at 20:57:17 Nice job Dave. Love the way you found a simple solution for the tooling. Looks to me like your Forstner bit has carbide blades. You're gettin ready to put some serious torque to that rear wheel.
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TheSneeze

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Re: Beefing up the Clutch
Reply #59 - 01/10/22 at 21:34:47

Seems to me a Forstner bit is a lot like a piloted spot facing end mill. A search on forstner bits came up mostly with wood cutting tools. I realize aluminum is softer than steel, but I have used mostly steel working tools. This is when I needed a spot face for a press in stud head to clear the brake shoes in a drum brake. Similar designed tool, different name.

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Every twenty minute job is a stripped thread away from being a three day ordeal.

'87 LS650h Savage Street Tracker
'86 LS650g Savage (parts bike)
'81 Kawasaki KZ750e ELR tribute

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