Hydraulic Clutch Again

jimmythetrucker · Full Member Joined: Mar 12, 2008 Posts: 1283

I searced "hydraulic clutch" and found a bunch o' posts by guys who wanted to do it but none from anyone who's actually done it. All of them were from, like, 2006.

So it's two years later: Has anybody at 650rider done a hydraulic clutch conversion yet? How did you do it? What parts did you have to scrounge? How much did it end up costing you?

Let me know, please. I'm sure there are others who are interested, too.

Thanks!

jimmy

dwyatt · Posted: October 4, 2008, 11:58 am Post subject: Re: Hydraulic Clutch Again

Same here when I was considering it. I finally just started it anyway. I bought a Magura hydraulic clutch master cylinder/lever from eBay for $75, then all you have to do is center it over the hole the worm gear was in, drill mount holes and bolt it on. The only thing left is to get a longer clutch push rod to fit since the distance is a little longer, depending on how you mounted it.

I'm out of town now, but will go insearch of a rod when I get home week after next. Should be able to get a 5/16" rod at Lowes or Home Depot and cut to fit. This part is way easier than you would think. Since I haven't put a rod in yet, I haven't had a chance to actually try it, I sure hope it takes care of the worm gear adjustment issues and should make for a smoother, easier pull.

There is more information on the 650 Garage web site. I can never post pictures here, but look in my account and I have several pictures of my bike with this on it.

Cafe_Shop · Posted: October 4, 2008, 1:17 pm Post subject: Re: Hydraulic Clutch Again

Here's the way I did it. So far. I still have to make the longer pushrod that dwyatt mentioned in his post.

Parts:

$23 - Spare Side Cover (didn't want to trash the original just in case)
$26 - 87 VFR700 Clutch Slave Cylinder
$50 - 98 VFR800 Clutch Master Cylinder
$50 - 98 VFR800 Brake Master Cylinder (to match)

I centered the clutch actuator hole on my drill press using a hole saw the same size.

Clamped it down.

Then I cut a hole large enough for the slave cylinder.

Then I used a larger hole saw to cut clearance for the sides of the slave cylinder.

Using a disk sanding attachment, I sanded an area flat large enough to mount the cylinder.

Now I have to figure out the correct length for the pushrod. I'll have to get back to you guys on that.

jimmythetrucker · Full Member Joined: Mar 12, 2008 Posts: 1283

I suppose the pushrod is going to be different lengths, depending upon which brand/type slave cylinder you used.

Cripes! That looks like an easy conversion. Just connect brain to fingers before engaging drill press, and it'll almost fall together for you.

Nice work!

yamaman · Posted: October 4, 2008, 11:16 pm Post subject: Re: Hydraulic Clutch Again

www.xs650.org.au/improving.htm

yamaman · Posted: October 4, 2008, 11:26 pm Post subject: Re: Hydraulic Clutch Again

just a thought on the push rod, I once put a set of adjustable push rods on a V8, perhaps one of these is close!

dwyatt · Posted: October 5, 2008, 1:48 am Post subject: Re: Hydraulic Clutch Again

Way easier than it would seem for this modification. Last person in needs to delete the post to keep our little secret so everyone else will think we're mechanical geniuses .....

Landmonster · Full Member Joined: Mar 11, 2009 Posts: 13

Any progress on the hydraulic clutch? Thinking of doing one myself

dwyatt · Posted: March 20, 2009, 1:54 am Post subject: Re: Hydraulic Clutch Again

Easy Peezy and very smooth. You can do it in two beers time.

dwyatt · Posted: March 20, 2009, 1:55 am Post subject: Re: Hydraulic Clutch Again

Easy Peezy and very smooth. You can do it in two beers time.

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Yamaha xs650