tuusinii
Pro
Posts: 1031
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posted April 04, 2004 10:52 PM
Clutch - again...
So have this little question about the clutch of the ZX12. This is a quote of TurboBlews comment on past thread Has Your clutch failed...:
quote:
Pardon my ignorance, but most of the '00 & '01 owners have known about *weak* clutch issues since April or May of 2000.
I foolishly toasted my clutch at the dragstrip, but I was fully prepared for the consequences. Upon disassembly I found *other* possible weak points.
I called a local dealer and they gladly warrantied the clutch. Of course they installed it incorrectly, but I went 10,000 miles pretty much trouble free.
Issues that need to be addressed are:
-Better oil delivery to the clutch pack. (Kawi addressed this)
-Heavier springs for the clutch
-Not offsetting the last clutch fiber
A few of shadetree solutions were:
-Flat spotting the puller shaft (costs nothing with access to a grinding wheel)
-EDMing the puller shaft 20 thousandths to allow more even oil flow ($30 at any machine shop
-Shimming the stock springs with sparkplug washers. (cost is barely $.50)
-Aligning the clutch pack so last fiber wasnt offset (free)
-installing an extra steel to get maximum wear out of the clutch (5.89 from RA.com plus shipping) (or free)
-Insuring clutch cable had proper slack
High dollar fixes were:
-Muzzy hub kit $300
-Machinist labor duplicating Muzzy kit $100
-Billet basket $360
-Lockup $600
So I have one question about the "fixies"... Why not offsetting the last fiber? Why Kaw says You should and what it helps if You Not. Cant see what it does? Anyone?
  
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TurboBlew
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posted April 04, 2004 11:46 PM
Offsetting the last fiber on the stock basket does not allow for full wear of the clutch. The tang between the fingers is shallow in every other one on the stocker and the tab on the fiber bottoms out early.
Aligning the fiber allows you to get some more wear out of the clutch pack.
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tuusinii
Pro
Posts: 1031
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posted April 05, 2004 01:08 AM
Thanks...
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tuusinii
Pro
Posts: 1031
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posted April 05, 2004 03:36 AM
And still one question: If i want new harder springs do I go with the ones for 02/03/04 the 92145-1087. For me its easiest and cheapest to get OEM parts. So are those the ones?
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TurboBlew
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posted April 05, 2004 03:45 AM
None of the OEMs are harder except for the ZX6r... which I dont know what year or part #s
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harryzx-12
Needs a job
Posts: 3643
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posted April 05, 2004 08:37 AM
 Edited By: harryzx-12 on 5 Apr 2004 09:38
2000 ZX-6r springs is what I have had in my bike for over 3 years now and the clutch does not slip. Change all 6 springs.
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"Life should NOT be a journey to the grave with the intention of arriving safely in an attractive and well preserved body, but rather to skid in sideways- Body thoroughly used up, totally worn out...Screaming "WOO HOO, What a Ride !!!"
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Ninjaman12R
Needs a job
as a Deal's Gap tour guide.
Posts: 4767
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posted April 05, 2004 12:09 PM
STFU Harry.......
Harry nobody cares about your ZX-6 powered "Ass Porting Machine". 
Oh yeah, and about the clutch. Just buy the muzzy kit and be done with it. 
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TurboBlew
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posted April 05, 2004 03:35 PM
Amen sista!
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CrotchRocket
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Bracket Racing with Betsy
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posted April 05, 2004 06:14 PM
Tuusinii, the OEM 1087 clutch springs are excellent...Not as stiff as the ZX6r springs ( OEM 1881 ) and with the 1087 springs your clutches will last a little longer!!!
If you want clutch longevity then get an OEM ZX12 hub from a 2002/03/04, use 12 all same size frictions, 11 1.6 steels, 6 1087 springs and put it into your 2000...You will not get any better clutch set up than that!!!
If you want to get a billet basket then order a 2002 basket with the gear from Muzzys!!!
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tuusinii
Pro
Posts: 1031
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posted April 05, 2004 10:53 PM
Thanx.
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EastBayDave
Needs a job
Posts: 2245
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posted April 11, 2004 05:40 AM
now someone tell me why my pressure plate just spins & spins after Muz basket & clutch install? Even tried an extra steel & fiber, but no lever at all....
I phked up something.......shitola...
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02' ZRX1200
00' ZX12R sold
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TurboBlew
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posted April 11, 2004 07:20 AM
Dave, you have to line the plate up with the grooves. It just doest go back any old way. YOu have a 1 in six chance getting it correct.
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EastBayDave
Needs a job
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posted April 11, 2004 07:28 AM
Edited By: EastBayDave on 11 Apr 2004 08:29
quote:
Dave, you have to line the plate up with the grooves. It just doest go back any old way. YOu have a 1 in six chance getting it correct.
uh...."line the plate up w/the groves"...can you elaborate please?
I spent the whole day yesterday taking the clutch/billet basket/hub in & out, in & out, in & out. WTF am I doing wrong?
I know it's gotta be something simple & stupid, otherwise I wouldn't discover the wrong way to do it! :P
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Enjoy the ride!
02' ZRX1200
00' ZX12R sold
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entropy
Moderator
Posts: 8671
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posted April 11, 2004 07:40 AM
if you have the right stack height, i.e. 10 2mm steels, 11 fibers, OR 11 1.6mm steels and 12 fibers, the pressure plate will engage the basket and will not spin.
do this BEFORE you have put the springs on.
Like TB says, you have a 1 in 6 chance of hitting it right. When it is right the PP will slide on a bit deeper than when it is wrong. Try placing the PP over the plates and see if it goes on nice n' tight against the plates. If not, rotate it 1/6th, try again, and so on. When it sits right on the plates, then you can put on the springs.
Explaining this is like trying to talk someone thru tying their shoes over the phone. Nothing to it once you've done it.
EBD, if this is flumoxing you send me a PM and i'll give you my tel number and talk you through it!
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TurboBlew
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posted April 11, 2004 08:15 AM
There are six holes in the clutch hub pressure plate. Mark one of the holes for reference with a marker. Try it in position one (marked hole), then turn it clock wise until you try the pressure plate in every position.
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entropy
Moderator
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posted April 11, 2004 08:43 AM
if you are in the Southern hemisphere turn it COUNTER clockwise...
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EastBayDave
Needs a job
Posts: 2245
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posted April 11, 2004 08:57 AM
thanks guys; going out to the geerage to try it right now....report back later....
can you believe I've had this laying around the garage for 2+ years before installing it? Doh!!! :P
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Enjoy the ride!
02' ZRX1200
00' ZX12R sold
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EastBayDave
Needs a job
Posts: 2245
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posted April 12, 2004 06:07 AM
Thank you ALL for the good info!!! I was one notch off; got it fully installed & adjusted yesterday. Ran the bike, no funny noises; ran it thru the gears, so assuming everythings cool. Getting the fairings back on today (got a couple days off), so I will be riding hopefully later today!! Yeehaaaaa!!
Feels a bit stiffer too....zx6 springs?
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Enjoy the ride!
02' ZRX1200
00' ZX12R sold
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EastBayDave
Needs a job
Posts: 2245
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posted April 12, 2004 03:56 PM
bu....waaaa!!!!........ooooohhhhh..........b'waaaaaa...........splooge!
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Enjoy the ride!
02' ZRX1200
00' ZX12R sold
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