Z650 refresh...

[KWACKERZ1]

Could you just qualify for me what your saying,
Z650 clutches standard are 5 spring aluminium fingered baskets is that correct?
Earlier z1000 and J's are 5 spring Steel baskets do these fit z650's as well?
and could they be used on later engines?
Later Gpz11 unitrack ones I believe are 6 spring,
so do the GSXR clutches have the same spacing?

Its just that I might have a clutch basket spare in a box of bits but would need to check what its from?

[MDM]

I can't remember what the 650 clutch is like - this "650" has been fitted with a Unitrak 1100 lump for the past 23 years...
So it's the 1100 engine that I'm talking about here
It's fitted with the usual Unitrak 6 bolt clutch (and aluminium basket), and while Rob has suggested fitting an earlier steel basket with it's five bolt arrangement, I have spares for the six bolt, but also a five bolt clutch basket that is also aluminium... and has a different spline on it as well, to confuse matters.
And the GSX-R one is a different six stud spacing (if, indeed, the one I have here is intended for a GSX-R?...)

[Al]

You could buy APE 15% (i think) stronger clutch springs and use an extra plain plate and a few other tweeks until such a time as you can locate a six spring lockup.
You could still use the extended cover as well and drop the lockup plate in when you find one.
Those two alterations will be secure upto about 130 BHP and they are there all the time unlike the lockup which doesnt operate until higher revs!!!
AL

[MDM]

I've got APE springs fitted Al and your suggestion looks like being the way forward
Now progress has been delayed by the loss of the bolt that holds the alternator onto the end of the crank... argh! anyone got a spare, or know the dimensions?

[KWACKERZ1]

Z-power stock them as I bought one recently.

[MDM]

Nice one, thanks! I'll call Z-Power today

[MDM]

New rotor bolt fitted, and tightening to spec 95ft-lb began... but didn't feel right, so pulled out again. And...

.. bollocks.

[Al]

Clutching at straws; is that an Electrex World rotor? RO3 stamped on it somewhere. If it is and it has a keyway cut in it for a woodruff key does it have a crack running through the keyway?
I believe the effective length of a bolt is one and a half times its diameter so i would have no issues cutting off the damaged part so long as it didnt flatten the threads on its way out!!
I had my current crank overhauled by SEP about ten years ago. I specifically asked them to clean out that thread for a more or less identical reason.
AL

[MDM]

No clutching there Al, you have a hard hold of my straw!
Yep, it's an Electrex rotor; yep it has R03 stamped on it; yep it has a keyway; but no, there's no crack in it.

[MDM]

On closer inspection, the following showed itself.
The copper (brass?) thrust washer that sits at the rear of the ring gear had been forced into a cone shape.

[MDM]

As you can see from the pic, it was too big to sit within the ring gear, as it should. But then, this was the thrust washer intended for the Unitrak, which is too big for the Electrex rotor, which needs one from an earlier 1100 with has a smaller OD. This was knowledge all passed on via Facebook, thanks to Neal Conway.
And, apparently, the Electrex rotor needs to have the crank bolt shortened to suit!
So, it's met the kiss of the grinder, and I also reduced the OD of the washer with the belt sander so it sits in the recess at the back of the ring gear..
Although I am considering using the spare washer I have - reduced in size to suit - rather than the one that had been forced into the cone shape...

[Pigford]

Glad to see you have "overcum & triumphed"

[zed1015]

Looks like you have the wrong thrust washer on the damper side..
The plain one goes on the other side of the roller bearing next to the starter clutch and the one on the damper rubber side should be much thicker,have oil grooves and a tapered recess that faces the crank.

15571829791_bf0dd0eccd.jpg (59.37 KiB) Viewed 6268 times

[MDM]

Ahah! Thanks Rob, correct bush ordered now

[MDM]

New thrust washer purchased, and waited for, received, fitted and all back together again.
And then, once the starter and alternator gubbins was all back together, I happened to find a glass jar, containing some bits...


... yep, the very bits that I had fucked about trying to find, then ordering (wrongly), re-ordering (correctly), waiting for and then fitting...