Hydraulic clutch conversion 2v big block

[Rick4003]

I just want to share my alternative take on the hydraulic clutch conversion here also as I know there is a lot of people who doesn't drift over to the build section of the forum.

My bike was converted to hydraulic clutch when I got it with a MotoSpezial clutch slave cylinder.
The MotoSpezial slave cylinder looks like this:


It replaces the clutch arm and throw out bushing and seals into the rear of the gearbox.

Exploded view of the cylinder:


I generally like the concept but didn't like the way that the bleed screw was fitted just behind the u-joint and pretty difficult to get to when bleeding. Also with the hydraulic line attached I could not turn the cylinder enough to get the bleed screw on top.

What I really wanted was a clutch cylinder in the same style but with a remote bleed screw on the side of the bike so I didn't need to take the bike half apart for bleeding the clutch.

This the exploded view of my own design slave cylinder:


The above picture is before welding the cylinder together. The small bushing in the middle goes in the hole in the gearbox and pushes on the throw out bearing. The piston is on the right and is not yet assembled. The little push rod that is in between will connect the piston and the throw out bush when installed. A recessed hole is drilled in both the piston and the bushing to fit the push rod. The recess also makes sure that most of the sideways pressure on the throw out bushing is eliminated as the force is transferred close to the throw out bearing. Imagine the difference of pushing sideways on the lid of a can versus pushing sideways on the bottom center. It is easy to push over the can if you push sideways on the lid, but almost impossible to tip it over when pushing on the bottom.
Concept drawing:


Finished welded clutch cylinder and parts on the table.


Cylinder mounted on gearbox. Bleed screw exits above gear arm and can be bleed without any disassembly of the bike.


Bleed screw exit:


The clutch cylinder uses standard hydraulic oil and there is no chance of the oil leaking into the gearbox if the seals should fail. This version uses a 10 mm mastercylinder piston and a 24 mm slave cylinder.

The clutch pull is quite easy but not feather light. If a 8 mm master cylinder piston was used I believe it could be very light action clutch. I have not yet got a change to measure the actual force required to pull the clutch.

Mounting is very easy although it does require the rear swing arm to be removed.

Further building pictures can be seen in the build thread on the build section.

-Ulrik

[Frenchfrog]

Very nice design improuvement and execution !

[Old Jock]

That is sweet

I wish I had the skill to fabricate like that

Hat's off to you Ulrik, thank you for the information and sharing your build

[Rick4003]

Very nice design improuvement and execution !

Thank you very much. It was only thanks to you that I found out what the old slave cylinder actually was. If you haven't told me I don't think I would have found it.

It just have normal x-ring seals in, so the brake fluid I topped it up with ruined the seals. So my fault in the end. Had I filled hydraulic oil on it in the first place, I don't think anything had happened to it.

-Ulrik

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[Huzo]

That is sweet

I wish I had the skill to fabricate like that

Hat's off to you Ulrik, thank you for the information and sharing your build

You operate in a different sphere Jock.
You do stuff that many people cannot...

[Huzo]

Beautiful conceptual idea and execution...
I could stare at that stuff all day. Thanks for sharing.

[Rick4003]

That is sweet

I wish I had the skill to fabricate like that

Hat's off to you Ulrik, thank you for the information and sharing your build

Thanks for the kind words Old Jock.

You are too humble with your skills, the level of detail you have put into your Magnis have inspired me to take a step up and make it as good as I can on my own bike.



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[Rick4003]

Beautiful conceptual idea and execution...
I could stare at that stuff all day. Thanks for sharing.

Thanks Huzo,
The pleasure is mine in sharing it. Especially if someone get something out of it.

-Ulrik

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[twodogs]

Now that is cool.Well done 

[John A]

That is very nice. I don't suppose you made several? Id buy that!

[Rick4003]

That is very nice. I don't suppose you made several? Id buy that!

I only made the one, but there is no reason why I could not make a small series if there is enough people who is willing to buy one :)

The current hydraulic advantage between the master and slave cylinder is 5.75. If I go down in master cylinder to 8 mm and up to 25 mm on the slave cylinder I would get an hydraulic advantage of 9.75. Then I believe I would get a very light and progressive clutch action.

The job has to wait until next year though as we will move from Bali to Denmark next summer and I will have the possibility of setting up my workshop.

-Ulrik

[Huzo]

I only made the one, but there is no reason why I could not make a small series if there is enough people who is willing to buy one :)

The current hydraulic advantage between the master and slave cylinder is 5.75. If I go down in master cylinder to 8 mm and up to 25 mm on the slave cylinder I would get an hydraulic advantage of 9.75. Then I believe I would get a very light and progressive clutch action.

The job has to wait until next year though as we will move from Bali to Denmark next summer and I will have the possibility of setting up my workshop.

-Ulrik

Would you still have enough throw on the clutch ?

[Huzo]

I only made the one, but there is no reason why I could not make a small series if there is enough people who is willing to buy one :)

The current hydraulic advantage between the master and slave cylinder is 5.75. If I go down in master cylinder to 8 mm and up to 25 mm on the slave cylinder I would get an hydraulic advantage of 9.75. Then I believe I would get a very light and progressive clutch action.

The job has to wait until next year though as we will move from Bali to Denmark next summer and I will have the possibility of setting up my workshop.

-Ulrik

Denmark you say?
May one enquire as to where exactly...?

[twowings]

Nice job! Too bad the OEMs have to meet a price point instead of superb engineering...

[Rick4003]

Would you still have enough throw on the clutch ?

That is indeed a question that needs to be addressed. I checked on my buddy's G5 with a cable pull clutch and the travel at the cable end of the clutch arm was around 10mm, I cannot remember the exact number anymore. But with the lever advantage of the clutch arm the total throw at the throw out bearing is something like 1 to 2 mm. I can always find out exactly what it is and choose the diameter to suit.

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[Rick4003]

Denmark you say?
May one enquire as to where exactly...?

Middle of Funen (Fyn), close to the town called Ringe.
If the house we are looking at is still available.

Are you planning another European trip?

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[Rick4003]

Nice job! Too bad the OEMs have to meet a price point instead of superb engineering...

Thanks [emoji4]

I don't think that a cable solution is a bad way to go. It is not too hard to make a good and light clutch action with a cable and it is dead easy to fix is something goes wrong. No seals to break or air to build up and bleed out. With a cable either it works or it doesn't. With hydraulic you can have a semi working clutch.

I know a guy who was a Yamaha MT10 and that thing has power in abundance and still runs a cable clutch with very light action.

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[earemike]

Bloody beautiful

[Huzo]

Middle of Funen (Fyn), close to the town called Ringe.
If the house we are looking at is still available.

Are you planning another European trip?

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Not planning, just gunna' go.
Certainly Mandello 2021 and one between then and now.
There's two rides I wanna' do.
#1 Melbourne to London on a V 85
#2 Cape Otway to Cape York and back on a CT 110. Honda (8,000 km)

[Rick4003]

Not planning, just gunna' go.
Certainly Mandello 2021 and one between then and now.
There's two rides I wanna' do.
#1 Melbourne to London on a V 85
#2 Cape Otway to Cape York and back on a CT 110. Honda (8,000 km)

That sounds like a good plan. That is usually also how I do road trips. We usually do a few main destinations on the way but no detailed planning for hotels, camp sites, tank stops and so on.

8000km on a CT110 will for sure be a good adventure [emoji4] maybe a good seat would be in order. I'm sure the bike will do it without any big trouble. The whole of Asia is transported by the same engine and it's descendents.
Good luck on the trips! You're welcome to stop by in den. Denmark if we are back at the time of your trip.

-Ulrik

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[Kiwi_Roy]

Very nice, great workmanship.
I like the way it is mounted on the original pivot point.

[Rick4003]

Very nice, great workmanship.
I like the way it is mounted on the original pivot point.

Thanks :)

Half the point of the design is that it should be able to be mounted without any modification of the gearbox casing. Then if anybody would like the idea it would be possible to just mount it up and don't worry about having to make some kind of machining on the case.
The original pivot point is the only thing that you can really use for mounting it, so pivot point it was :)

- Ulrik

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