in the clutch of things

[Bogdan Swider]

At 71k miles, for the first time, I inspected the clutch. Each friction plate measured 3mm; the service limit is 2.8. Anyone know what new plates measure ? I’m curious how much I shaved off. From what I could tell the steel plates looked fine. I replaced the springs. The old springs were slightly above or below the service limit of  33.1mm; the new EBC springs I got from Fred measured 37mm. Party on, Bogdan

[Jeff Saline]

Clutch Plates ? #ygrps-yiv-504559818 .ygrps-yiv-504559818ygrp-photo-title { CLEAR:both;FONT-SIZE:smaller;OVERFLOW:hidden;WIDTH:75px;HEIGHT:15px;TEXT-ALIGN:center;} #ygrps-yiv-504559818 DIV.ygrps-yiv-504559818ygrp-photo { BORDER-RIGHT:black 1px solid;BACKGROUND-POSITION:center 50%;BORDER-TOP:black 1px solid;BORDER-LEFT:black 1px solid;WIDTH:62px;BORDER-BOTTOM:black 1px solid;BACKGROUND-REPEAT:no-repeat;HEIGHT:62px;BACKGROUND-COLOR:white;} #ygrps-yiv-504559818 DIV.ygrps-yiv-504559818photo-title A { TEXT-DECORATION:none;} #ygrps-yiv-504559818 DIV.ygrps-yiv-504559818photo-title A:active { TEXT-DECORATION:none;} #ygrps-yiv-504559818 DIV.ygrps-yiv-504559818photo-title A:hover { TEXT-DECORATION:none;} #ygrps-yiv-504559818 DIV.ygrps-yiv-504559818photo-title A:visited { TEXT-DECORATION:none;} #ygrps-yiv-504559818 DIV.ygrps-yiv-504559818attach-table DIV.ygrps-yiv-504559818attach-row { CLEAR:both;} #ygrps-yiv-504559818 DIV.ygrps-yiv-504559818attach-table DIV.ygrps-yiv-504559818attach-row DIV { FLOAT:left;} #ygrps-yiv-504559818 P { CLEAR:both;PADDING-RIGHT:0px;PADDING-LEFT:0px;PADDING-BOTTOM:3px;OVERFLOW:hidden;PADDING-TOP:15px;} #ygrps-yiv-504559818 DIV.ygrps-yiv-504559818ygrp-file { WIDTH:30px;} #ygrps-yiv-504559818 DIV.ygrps-yiv-504559818attach-table DIV.ygrps-yiv-504559818attach-row DIV DIV A { TEXT-DECORATION:none;} #ygrps-yiv-504559818 DIV.ygrps-yiv-504559818attach-table DIV.ygrps-yiv-504559818attach-row DIV DIV SPAN { FONT-WEIGHT:normal;} #ygrps-yiv-504559818 DIV.ygrps-yiv-504559818ygrp-file-title { FONT-WEIGHT:bold;} ____________________________________________________________ Get Free Email with Video Mail & Video Chat!

[Jeff Saline]

Sorry list, Looks like Juno and Yahoo didn't want to work together on that last post. Here's what I sent. Best, Jeff <><><><><><><> <><><><><><><> Bogdan, I don't have the numbers you are looking for but maybe RevMaatin does. He changed his clutch plates at my shop a couple of years ago at the end of one of his Great Divide Rides. I seem to recall we measured his new and old plates but I'm sure I didn't keep any notes. I think he kept the old plates as they were still within service limits. According to my factory service manual supplement for 87-95 the friction plate thickness standard is 2.9-3.1 mm and the service limit is 2.75 mm. Steel plate warp standard is less than 0.2 mm and the service limit is 0.3 mm. Clutch spring free length standard is 34.2 mm and the service limit is 33.1 mm. My supplement for up to 2003 is in the shop. If you want me to check it let me know. Now my Clymers for 87-07 is a bit different. It says: Friction plate thickness is 2.80-3.1 mm new and 2.60 mm service limit. Steel warp is 0.0-0.2 mm new and 0.3 mm service limit. Spring Free length depends on the year: 87-95 34.2 mm new and 33.1 mm service limit. 96-on 38.7 mm new and 36.4 mm service limit. Hope this is helpful. Best, Jeff Saline ABC # 4412 South Dakota Airmarshal Airheads Beemer Club www.airheads.org The Beautiful Black Hills of South Dakota 75 R90/6, 03 KLR650, 79 R100RT <><><><><><><> <><><><><><><> On Thu, 11 Mar 2010 07:29:44 -0700 Bogdan Swider writes: At 71k miles, for the first time, I inspected the clutch. Each friction plate measured 3mm; the service limit is 2.8. Anyone know what new plates measure ? I m curious how much I shaved off. From what I could tell the steel plates looked fine. I replaced the springs. The old springs were slightly above or below the service limit of 33.1mm; the new EBC springs I got from Fred measured 37mm. Party on, Bogdan . ____________________________________________________________ Hotel Hotel pics, info and virtual tours. Click here to book a hotel online. http://thirdpartyoffers.juno.com/TGL2141/c?cp=2gwPQtSqlKot76bZpkvT9wAAJ1DWfJIDP-R0_NC3mMpGFS0kAAYAAAAAAAAAAAAAAAAAAADNAAAAAAAAAAAAAAAAAAATRAAAAAA=

[Bogdan Swider]

Re: [DSN_KLR650] Clutch Plates ? Very helpful as usual, Jeff. At some point I have to ride up to your neck of the woods and buy you a beverage. As I have a 95 it seems my plates have worn .1mm or not at all. The 34.2mm new OEM springs explains the stout pull needed on the 37mm EBCs; Fred warned me about that. Bogdan

On 3/11/10 7:52 AM, "Jeff Saline" salinej1@...> wrote:

Bogdan,   I don't have the numbers you are looking for but maybe RevMaatin does.  He changed his clutch plates at my shop a couple of years ago at the end of one of his Great Divide Rides.  I seem to recall we measured his new and old plates but I'm sure I didn't keep any notes.  I think he kept the old plates as they were still within service limits.   According to my factory service manual supplement for 87-95 the friction plate thickness standard is 2.9-3.1 mm and the service limit is 2.75 mm.   Steel plate warp standard is less than 0.2 mm and the service limit is 0.3 mm.   Clutch spring free length standard is 34.2 mm and the service limit is 33.1 mm.   My supplement for up to 2003 is in the shop.  If you want me to check it let me know.   Now my Clymers for 87-07 is a bit different.  It says:   Friction plate thickness is 2.80-3.1 mm new and 2.60 mm service limit.   Steel warp is 0.0-0.2 mm new and 0.3 mm service limit.   Spring Free length depends on the year:   87-95  34.2 mm new and 33.1 mm service limit. 96-on  38.7 mm new and 36.4 mm service limit.   Hope this is helpful.   Best, Jeff Saline ABC # 4412  South Dakota Airmarshal Airheads Beemer Club www.airheads.org http://www.airheads.org> The Beautiful Black Hills of South Dakota 75 R90/6, 03 KLR650, 79 R100RT <><><><><><><> <><><><><><><> On Thu, 11 Mar 2010 07:29:44 -0700 Bogdan Swider bSwider@...> writes:   At 71k miles, for the first time, I inspected the clutch. Each friction plate measured 3mm; the service limit is 2.8. Anyone know what new plates measure ? I’m curious how much I shaved off. From what I could tell the steel plates looked fine.   I replaced the springs. The old springs were slightly above or below the service limit of  33.1mm; the new EBC springs I got from Fred measured 37mm.   Party on, Bogdan .   ____________________________________________________________  Get Free Email with Video Mail & Video Chat! http://www.juno.com/freeemail?refcd=JUTAGOUT1FREM0210>  

[Kevin Powers]

On Thu, Mar 11, 2010 at 9:59 AM, Bogdan Swider wrote: Very helpful as usual, Jeff. At some point I have to ride up to your neck of the woods and buy you a beverage. As I have a 95 it seems my plates have worn .1mm or not at all. The 34.2mm new OEM springs explains the stout pull needed on the 37mm EBCs; Fred warned me about that. Bogdan

TwinHeadlight Ernie at Dakota Motosports makes a clutch arm mod that reduces the clutch lever effort. Ordering one has been on my to-do list for a while. http://www.advrider.com/forums/showthread.php?t=527547 -- Kevin Powers White Bear Lake, MN

[Bogdan Swider]

Very interesting, Kevin. I wonder if this system would fit into my Moose aluminum hand guard ? Bogdan

On 3/11/10 9:23 AM, "Kevin Powers" wrote: > > > > > > > > On Thu, Mar 11, 2010 at 9:59 AM, Bogdan Swider > wrote: >> >> >> >> >> >> Very helpful as usual, Jeff. At some point I have to ride up to your neck of >> the woods and buy you a beverage. As I have a 95 it seems my plates have worn >> .1mm or not at all. The 34.2mm new OEM springs explains the stout pull needed >> on the 37mm EBCs; Fred warned me about that. >> >> Bogdan > > > TwinHeadlight Ernie at Dakota Motosports makes a clutch arm mod that reduces > the clutch lever effort. Ordering one has been on my to-do list for a while. > http://www.advrider.com/forums/showthread.php?t=527547

[Kevin Powers]

Not a problem - it goes on the other end of the clutch cable on the right side of the engine. Kevin

On Thu, Mar 11, 2010 at 10:28 AM, Bogdan Swider wrote: Very interesting, Kevin. I wonder if this system would fit into my Moose aluminum hand guard ? Bogdan On 3/11/10 9:23 AM, "Kevin Powers" http://PowersHouse@...]PowersHouse@...[/url]> wrote: [quote] On Thu, Mar 11, 2010 at 9:59 AM, Bogdan Swider http://bSwider@...]bSwider@...[/url]> wrote: Very helpful as usual, Jeff. At some point I have to ride up to your neck of the woods and buy you a beverage. As I have a 95 it seems my plates have worn .1mm or not at all. The 34.2mm new OEM springs explains the stout pull needed on the 37mm EBCs; Fred warned me about that. Bogdan

TwinHeadlight Ernie at Dakota Motosports makes a clutch arm mod that reduces the clutch lever effort. Ordering one has been on my to-do list for a while. http://www.advrider.com/forums/showthread.php?t=527547 [/quote] -- Kevin Powers White Bear Lake, MN

[revmaaatin]

--- In DSN_KLR650@yahoogroups.com, Jeff Saline wrote:

> > Sorry list, > > Looks like Juno and Yahoo didn't want to work together on that last post. > > Here's what I sent. > > Best, > > Jeff > <><><><><><><> > <><><><><><><> > Bogdan, > > I don't have the numbers you are looking for but maybe RevMaatin does. > He changed his clutch plates at my shop a couple of years ago at the end > of one of his Great Divide Rides. I seem to recall we measured his new > and old plates but I'm sure I didn't keep any notes. I think he kept the > old plates as they were still within service limits. > > According to my factory service manual supplement for 87-95 the friction > plate thickness standard is 2.9-3.1 mm and the service limit is 2.75 mm. > > Steel plate warp standard is less than 0.2 mm and the service limit is > 0.3 mm. > > Clutch spring free length standard is 34.2 mm and the service limit is > 33.1 mm. > > My supplement for up to 2003 is in the shop. If you want me to check it > let me know. > > Now my Clymers for 87-07 is a bit different. It says: > > Friction plate thickness is 2.80-3.1 mm new and 2.60 mm service limit. > > Steel warp is 0.0-0.2 mm new and 0.3 mm service limit. > > Spring Free length depends on the year: > > 87-95 34.2 mm new and 33.1 mm service limit. > 96-on 38.7 mm new and 36.4 mm service limit. > > Hope this is helpful. > > Best, > > Jeff Saline > ABC # 4412 South Dakota Airmarshal > Airheads Beemer Club www.airheads.org > The Beautiful Black Hills of South Dakota > 75 R90/6, 03 KLR650, 79 R100RT > <><><><><><><> > <><><><><><><> > On Thu, 11 Mar 2010 07:29:44 -0700 Bogdan Swider > writes:

Bogdan, I arrived at Jeff's after the GDR and suspecting a damaged clutch from the mud we encountered during the ride. My riding compatriot, 'the klrbugeater' blew a clutch in the Wyoming Great Basin that required replacement. Having ridden the same conditions, and the clutch did feel different, I called Jeff, he ordered a clutch pack/steel spacers/springs and had them waiting for me when I arrived some 10 days later. When Jeff and I re-clutched ol' 98, the fiber clutch plates were in spec,showed only minimal wear over against the wear tolerance--all plates checked. However, one metal plate was discolored (suggested by the book to replace any discolored steel plate)--but not warped as checked on a granite table/flat service, but the springs were less than spec. Due to the nature of the purchase--special order, I elected to install the new clutch, metal shims, and definitely springs and have complete confidence in the installation and bike's condition. In retrospect, it was overkill--but I ride long distance and remote locations and I considered it cheap insurance and peace of mind. I still have the old plates in a bag; I would not hesitate to use them for another 27K miles. I would replace the one discolored plate and all the springs and would not hesitate to install them on a bike, or anyone elses bike for that matter. As a side note: why I went ahead and ordered the clutch for my own bike. Based on where we both rode, and the condition of John S./klrbugeater's metal plates that were heat treated to a beautiful blue, and clutch plates that smelled like a fire sale, the probability was high that I sustatined clutch damage as well. As it turned out, I needed springs and one plate at a minimum. We got beautiful service from the Kawi dealer in Riverton, WY. THE BEST. They dropped everything else they were doing, overnighted the parts and changed out the clutch on a Saturday afternoon with out overtime charges. simply the best. "We try to help a bike rider get back on the road, even if we have to stay late because most are working people and they don't need to spend their vacation waiting on a bike repair." I wish we had saved a metal disc/spacer. It would have made a wonderful souvenir. revmaaatin.

[SM]

Man, why do KLR riders have a reputation for being cheap? Put down the krupnik and just replace the friction plates and springs already. Sheesh, 71,000 miles. Thanks CA Stu A13

--- In DSN_KLR650@yahoogroups.com, Bogdan Swider wrote: > > > > > At 71k miles, for the first time, I inspected the clutch. Each friction > plate measured 3mm; the service limit is 2.8. Anyone know what new plates > measure ? I m curious how much I shaved off. From what I could tell the > steel plates looked fine. > > I replaced the springs. The old springs were slightly above or below the > service limit of 33.1mm; the new EBC springs I got from Fred measured 37mm. > > Party on, Bogdan >

[Bogdan Swider]

Re: [DSN_KLR650] Re: Clutch Plates ? Naw, I left the old plates in.......out  of loyalty and because they still looked so pretty. I did replace the springs. You’re right – if I wasn’t so cheap I’d be ridding a Harley CVO Ultra Classic instead of my beat-up anemic klr. Glad someone is aware of Krupnik, a fine honey liquor. FWIW there’s a barley soup by the same name. Last night, however, I drank some Old Grand Dad – cause they named it after me. Bogdan

On 3/11/10 11:16 PM, "Stuart Mumford" s2mumford@...> wrote:

        Man, why do KLR riders have a reputation for being cheap? Put down the krupnik and just replace the friction plates and springs already. Sheesh, 71,000 miles. Thanks CA Stu A13 --- In DSN_KLR650@yahoogroups.com , Bogdan Swider wrote: > > > > > At 71k miles, for the first time, I inspected the clutch. Each friction > plate measured 3mm; the service limit is 2.8. Anyone know what new plates > measure ? I’m curious how much I shaved off. From what I could tell the > steel plates looked fine. > > I replaced the springs. The old springs were slightly above or below the > service limit of  33.1mm; the new EBC springs I got from Fred measured 37mm. > > Party on, Bogdan >