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-   -   Clutch solution by Bilgebay - Bilgebay mod :) ( https://www.xt660.com/showthread.php?t=8611)

bilgebay 09-12-08 15:31

Clutch solution by Bilgebay - Bilgebay mod :)
 
2 Attachment(s)
Dear all,

I was having great difficulty with the force needed to operate the clutch. It was too stiff for me and and after 1 hour or so I was having cramps on my left hand.

Searching through the net I was unable to find a satisfactory solution and decided to go ahead with my own solution which was extending the clutch lever on the engine. It worked great for me and I wanted to share it with you guys. Please see the photos and let me know if you need any additional information. The only price you need to pay is to mention my name with the mod.

You can even aim for 70 mm as I saw it would be perfectly fine after I tried mine at 60mm. You will not believe how you did without this modification until now.

Best regards

Sedat Bilgebay

colros 09-12-08 16:18

Great mod, do you find you have enough travel to make the clutch work? :angry3:

I find that the standard lever still means that the bike drags the clutch, even with the Clutch adjusted up. :icon_shaking2:

CaptMoto 09-12-08 17:18

Well done, it is quite a smart way to fix that problem, in fact the longer the lever the lighter the action. Yet I am curious to understand if this was just a personal issue with you, that you have also encountered with other bikes as it is the first time I hear someone finding the XT's clutch too hard. Not being funny but how big is you hand?

bilgebay 09-12-08 19:05

Hi colros! Believe me there is no difference in the drag. I agree, when you engage the first gear it kicks the bike both with and without the modification. If you carefully check the lever photo I kept the original hole in place ( at 40mm) I have added another hole at 50mm and yet another at 60mm. I tried all three of them again and again to be on the safe side. No difference in that clunking at all. The clutch is functioning in a very narrow angle anyway, so this is not an issue. You have the usual recommended gap at the hand lever even at 60mm hole.

Hope this answers

bilgebay 09-12-08 19:15

Captmoto, I must admit that my hands are not that strong anymore after so many years of mouse driving in front of the computer. However, I am riding another bike which has a much lighter clutch. After the XT, I can tell you the other bike, which is a Honda, got even lighter which is an indication my hand growing stronger. Still I found the XT clutch intolerable. Besides there ara the hydraulic clutches on the market claiming a 20% increase in the force you apply to the lever so there must be a demand for this. My solution is offering a 50 % increase in the force you need to apply or 33 % less demand for force, ie instead of applying a 5kg force you only need 3.3 kgs.

Regards

Sedat

Mattie 09-12-08 19:38

I am sure you will get used to the XT clutch. My hand/wrist was sore for a couple of weeks after moving to the XT from my DT125, but now it is fine and no problems at all with it. I have to operate the clutch with only two fingers and as the rest of my left hand is missing.

Bear 09-12-08 20:55

Hmm nice mod, Ive never considered the clutch to be hard for me! I only use four fingers at trafic lights or junctions for saftys sake and two for gear change on the move!
Well done though :applause:

maxwell123455 09-12-08 21:20

Never had a problem with the clutch as ive massive strong hands (must be too much :eusa_dance:) but that is a cracker idea of a mod, good bit of engineering there, might have to use it on my dads honda varadero as that clutch is like a brick compaired the XT's

colros 10-12-08 09:54

Quote:

Originally Posted by bilgebay (Post 75901)
Hi colros! Believe me there is no difference in the drag. I agree, when you engage the first gear it kicks the bike both with and without the modification. If you carefully check the lever photo I kept the original hole in place ( at 40mm) I have added another hole at 50mm and yet another at 60mm. I tried all three of them again and again to be on the safe side. No difference in that clunking at all. The clutch is functioning in a very narrow angle anyway, so this is not an issue. You have the usual recommended gap at the hand lever even at 60mm hole.

Hope this answers

Sure does, many thanks

I do find the Clutch can be heavy when in town. But my Left wrist has been broken in the past and I tore the ligaments in the Thumb. So not what you call a shining example.

Keep up the good work. :WellDone_OROQR1:

maxwell123455 10-12-08 09:58

I think this could be a new mod that can be added to the list us XT boys and girls have designed/made

bilgebay mod

got a ring to it:icon_compress:

Kev 10-12-08 10:08

All ready in the modfication index.:sign16:

Denny 10-12-08 11:19

Forum'a hosgeldin bilgebay ;)

I never had a problem with the clutch either, but you did and fixed it...well done :thumbsup:

bilgebay 10-12-08 12:20

Teşekk�rler Denny!

Kev, I am glad I did something for the community. Thanks for adding the solution to your mods list.

All the best

Sedat

bilgebay 10-12-08 12:24

Maxwell, thanks for your nice comments. Youcan go and help your dad out with that Varadero now :)

Best

Sedat

Outtashape 02-04-09 22:33

Re Clutch Mod
 
I must admit that in the short time (1 month) I have been riding my new XT; I have found the clutch a a tad heavy in traffic compared to my previous bike (ZZR 600). Maybe it's just my age, but will consider this mod when warranty expires, unless my left forearm develops in the meantime :icon_sunny:!!

Kev 02-04-09 23:25

I have not tried this mod myself, I am sure it will benefit anyone who feels their clutch is a little heavy.

I do not think it will effect your warranty as long as there is free play after the mod is done in the clutch lever.

Stinky Pete 23-04-09 09:21

Where did you get the new lever or how did you mod it?

Thanks.

Kev 23-04-09 12:48

Quote:

Originally Posted by Stinky Pete (Post 90998)
Where did you get the new lever or how did you mod it?

Thanks.

It was cut, made longer & re welded

sbdevro 02-06-09 14:51

Quote:

Originally Posted by bilgebay (Post 76013)
Teşekk�rler Denny!

Kev, I am glad I did something for the community. Thanks for adding the solution to your mods list.

All the best

Sedat

Thanks for listing this mod on here Sedat, it's a very simple engineering solution (aint they always when somebody else has thought of it :002:)
I will def give this ago before I consider parting with my hard earned for a hydrualic set up.
:YouRock:

dagreek 11-07-09 18:49

Hi guys a, a question about the modification, how would I set about extending the clutch lever? Did you weld and extra piece of metal on it or is it a new longer lever that you got somewhre else or what? Sorry if I sound stupid, Im new to this...
Thnx!

EDIT:
Erm this post turned up in a slightly different thread than where I posted it somehow, and my answer is already answered above.

Quote:

It was cut, made longer & re welded

bilgebay 17-07-09 12:19

Sorry, I was away from my computer for quite sometime... I will try to make a sketch of what we did to extend the arm asap. In essence the new and old pieces are overlapping and welded together

cheers

sedat

bilgebay 17-07-09 12:23

Quote:

Originally Posted by sbdevro (Post 96475)
Thanks for listing this mod on here Sedat, it's a very simple engineering solution (aint they always when somebody else has thought of it :002:)
I will def give this ago before I consider parting with my hard earned for a hydrualic set up.
:YouRock:

hi sbdevro... when you do this you will realize that the result is much better than your hydraulic lever :) because the gain is much more.

regards

sedat

jiauka 17-07-09 12:51

Great mod, I have turn the lever position in order to have a better moment arm and I will do your mod as son as my brother returns me the arc soldering machine.

thanks for sharing,

j.

bilgebay 21-07-09 09:54

1 Attachment(s)
Quote:

Originally Posted by bilgebay (Post 100625)
Sorry, I was away from my computer for quite sometime... I will try to make a sketch of what we did to extend the arm asap. In essence the new and old pieces are overlapping and welded together

cheers

sedat

As promised, here is the sketch describing how I modified the lever arm. Sorry for my ugly hand writing and awkward sketch. It appears I am losing my ability to write or sketch with my hand due to extensive mouse and keyboard usage :)

Best

Sedat

theclowncrusty 26-08-09 23:39

Hi all, not having picked my bike up yet, my question is, is the arm ally or steel? as i have mig welder but no way of doing ally welding. Would it be best to buy a new arm to mod just in case it all goes pear shapped?blowup
Mark (Crusty)

bilgebay 27-08-09 21:12

Hi Mark,

if things go bad and you cannot weld the 2 pieces together you can even use 2-3 M5 screws to hold them together. looking at the rust on my lever i can say the lever is steel and sort of anodised,galvanised what so ever...

regards

Sedat

mrfijjitt 12-04-10 20:18

Very impressed.
Extended my lever by about 12mm and it is so much nicer. esp in traffic.

:)

SimonRoma 22-02-12 16:03

Brilliant idea well done!!! My mate has a problem with athritis in his left hand and therefore loads of problems to use the clutch. I will propose that we make this mod straight away!! Thanks guys.

scarab1987 22-02-12 16:13

i made it.it is at least 50% lighter.

chussel 15-06-13 07:32

Thanks for this mod. My husband has just fitted this onto my XT and now it really kicks to get into first gear. Will this damage anything?

Petenz 15-06-13 07:45

If hand strength is a real issue you can put a Rekluse EXP auto clutch in...
Then the clutch lever becomes pretty much obsolete but you still retain
the manual clutch if required.. yer have a 660cc postie bike "CT110"...
But a kool mod ... The bilgebay mod:winner:

GStry 25-08-14 23:27

bilgebay, well done with this mod, I broke my left wrist quite badly a year ago and am sure this is going to help. :eusa_clap:

brmourato 02-02-15 11:48

Quote:

Originally Posted by bilgebay (Post 75869)
Dear all,

I was having great difficulty with the force needed to operate the clutch. It was too stiff for me and and after 1 hour or so I was having cramps on my left hand.

Searching through the net I was unable to find a satisfactory solution and decided to go ahead with my own solution which was extending the clutch lever on the engine. It worked great for me and I wanted to share it with you guys. Please see the photos and let me know if you need any additional information. The only price you need to pay is to mention my name with the mod.

You can even aim for 70 mm as I saw it would be perfectly fine after I tried mine at 60mm. You will not believe how you did without this modification until now.

Best regards

Sedat Bilgebay

I want to do this mod to my bike. Riding one full morning in sand made me realize how hard the clutch is... or how weak I am:icon_frown:
Can you please explain how you removed the arm lever and the clutch cable to do the mod? I have looked at it and couldn't figure out how to remove it...
Thanks in advance.

brmourato 24-02-15 15:55

Nevermind... Finally made it. Here it is:
http://i59.tinypic.com/etehww.jpg
http://i58.tinypic.com/2enaxhj.jpg

Jed 23-03-15 21:10

Quote:

Originally Posted by bilgebay (Post 75869)
Dear all,

I was having great difficulty with the force needed to operate the clutch. It was too stiff for me and and after 1 hour or so I was having cramps on my left hand.

Searching through the net I was unable to find a satisfactory solution and decided to go ahead with my own solution which was extending the clutch lever on the engine. It worked great for me and I wanted to share it with you guys. Please see the photos and let me know if you need any additional information. The only price you need to pay is to mention my name with the mod.

You can even aim for 70 mm as I saw it would be perfectly fine after I tried mine at 60mm. You will not believe how you did without this modification until now.

Best regards

Sedat Bilgebay

Thanks for this mod, I badly need this as I find my hand getting very painful. Think I need both a welder and a doctor!

I wonder if any other bikes use the same spindle size with a longer lever length on the clutch pull? Will go looking.

Petenz 24-03-15 07:37

Quote:

Originally Posted by Jed (Post 208075)

I wonder if any other bikes use the same spindle size with a longer lever length on the clutch pull? Will go looking.

You may find a gear lever that will fit the spline....
shorten it / drill a hole & fit the cable holder on to it...

Kev 24-03-15 11:04

Make sure you bend the outer cable bracket so the cable pulls dead centre.

I have also just done this mod to my MT09 works well.

Chrissyboy 14-07-15 12:13

Clutch arm removal method
 
Hey guys,

So i've done my snorkel and co1 and the bike seems slightly better filtering and town riding, i'll get the fuel mod after next pay day however this clutch is killing me in the stop start world of Sydney!

This is by far the best fix i've seen mainly for its simplicity. Could anyone who's done it do a walk through for getting the clutch arm off ready for modification?

I'm hoping to find someone who can help out with the fabrication as i have no welding equipment. If i can get it off i may take it to a metal 3D printers and see what they say!

Cheers

Chris

keithy2 14-07-15 17:28

clutch mod
 
Quote:

Originally Posted by chussel (Post 188669)
Thanks for this mod. My husband has just fitted this onto my XT and now it really kicks to get into first gear. Will this damage anything?

If it kicks more after doing the modification then the clutch is dragging ie not releasing enough, adjust the free play to the required setting 10mm at the end of the lever. Do not take all of the free play out of the cable or you will destroy the clutch.

keithy2 14-07-15 17:38

clutch mod
 
Regarding the clutch mod, the range of movement of the cable is set by the handlebar lever if the clutch actuator lever is lengthened as per the clutch mod then range of disengagement is reduced. If it still fully disengages then no worries, otherwise it will drag more.


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