New Clutch cover

[stainlesscycle]

i can't get to installing it until next week - have 2 vintage bikes to prep for this weekend... -

will report back what needs to happen to make it work.

[stainlesscycle]

Originally Posted by HenrikSchmidt

I also heard that it would fit the older bikes, from a reliable source

From:http://www.gasgasrider.org/forum/sho...+cover&page=23
Quote:
Originally Posted by Clay,
When we were in Spain in May, one of the tech guys showed us the new clutch cover and said it would fit on older bikes. It has a kind of funnel shape molded into it that channels the oil directly into the clutch basket.

DOES NOT FIT 2011 and earlier. as stated, 10 + gaskets would be needed. there's at least 1/4" of spacer needed. maybe someone could make one............

[HenrikSchmidt]

A 1/4" whats different on the new clutch? Lower stack? If you have a friend with a lathe or a mill, you could make a spacer from your old cover very easy. or just sketch it up on a sheet of 1/4" alu plate and cut it out with a hacksaw

[Jakobi]

Does this mean the 2012 model uses a different RHS engine cover as well as the new clutch cover?

or the 2012 clutch basket doesn't sit out as far as the 2011 and previous..

I'm guessing later is more likely.

[stainlesscycle]

Originally Posted by HenrikSchmidt

A 1/4" whats different on the new clutch? Lower stack? If you have a friend with a lathe or a mill, you could make a spacer from your old cover very easy. or just sketch it up on a sheet of 1/4" alu plate and cut it out with a hacksaw

i have a lathe and i thought about turning my whole old cover down to make a spacer, but after looking at it, i think it's easier said then done... the thickness of the spacer needed appears to be more than the height of the screw bosses on the old cover - and the new surface that would mate with the new cover wouldn't seal (or that's at least what it looks like to me)... and it looks like brake lever would foul the new cover. and you'd need to take into account the height of the pressure plate when you pull the clutch lever in so the pressure plate doesn't rub on the cover.

there's a couple of potential reasons the cover won't fit, don't know which one it is:

a: inner clutch cover is different on 2012 (most likely)
b:basket and hub are smaller on 2012 - not likely - that would mean different plate thicknesses/new stack height...
c:basket and hub recess in 2012 case more - not likely
d:clutch gear narrower - not likely - this would mean a total redesign of everything driven off the clutch gear.. and this would mean a lot of new parts..

i've gotta look at the 2012 fiche and see what part numbers are new to see if i can figure it out.

there may be a simple solution, but without a 2012 for me to actually look at, it's a crap shoot..

[stainlesscycle]

Originally Posted by Jakobi

Does this mean the 2012 model uses a different RHS engine cover as well as the new clutch cover?

or the 2012 clutch basket doesn't sit out as far as the 2011 and previous..

I'm guessing later is more likely.

yeah, the 2012 clutch does not protrude as much, so that means the inner clutch cover is probably taller to make it appear that way.

[stainlesscycle]

had a quick look at parts fiches..

ME650002510 - inner clutch cover 2012

ME250132001 - inner clutch cover 1999ish - 2011 i believe

so that's probably the difference....

[stainlesscycle]

Originally Posted by HenrikSchmidt

I also heard that it would fit the older bikes, from a reliable source

From:http://www.gasgasrider.org/forum/sho...+cover&page=23
Quote:
Originally Posted by Clay,
When we were in Spain in May, one of the tech guys showed us the new clutch cover and said it would fit on older bikes. It has a kind of funnel shape molded into it that channels the oil directly into the clutch basket.

maybe clay can chime in and show us how this can be adapted....

[Jakobi]

While your fichin it up.. Any chance of seeing what other parts are different in the 2012 head?? reports are it super smoooth!

[stainlesscycle]

head and cylinder the same. crank end weight is different.. it's full circle like the early 300 i have here (99) (that would account for most of the vibe reduction i bet) - and from the pics, looks significantly smaller.. also no nylon stuffers on 12... entire crankshaft assembly has different part number (probably due to the elimination of stuffers) i bet the right side crank shaft is the same - just swap counterweights..