Karson's Barnett clutch swap, DMM HID lights, bar risers

[Karson]

Draining the oil as we speak and getting ready to pull the side cover off to put the Barnett Clutch plate/springs on. Will probably run the black springs and see how it goes, which from my understanding are the in between the gold (least) & green (most) in terms of spring force. Thanks, jaxon. Word on the street is the green ones aren't long enough, for whatever reason, in the batch currently being shipped. But it's been brought to Barnett's attention and they're fixing it as we speak.

Be sure to have an extra gasket on hand, you MIGHT be able to salvage the old one, but for ~$20 just replace it with a new one. Part# 23P-15461-00

Also, I plan on using some reflective heat tape to cover the underside & top of the airbox. Hopes here are that the dash readout are somewhat more realistic to ambient outside air temperatures. Might mess with shortening the snorkels a little, too.

Next will be swapping out the DDM tuning HIDs for Morimoto's. One of my DDM ballasts is on it's way south, and I like how the igniter & ballast on the Morimoto's are all one self contained box. Their motorcycle specific relay harness is insanely long, but I'll shorten it. Source: theretrofitsource.com

Colorado was the icing on the cake that the stock handlebar height is just too short. At 6'3", I must have midget arms. When standing, the grips are in the pads of my finger tips. Not necessarily confidence inspiring to ride how I want to ride when I'm in the mecca of some of the best offroad riding in the CONUS. Gonna try basic 2" Rox risers and long lines in preparation for a trip in Arkansas later this year...

Will update with reports as installations progress. Will be cell phone pic heavy




[Modified the thread title to make it useful from "Time to have some fun" - CW]

 

[clint64]

Re: Time for some fun...

That does sound like fun. Keep us posted.

 

[avc8130]

Re: Time for some fun...

Karson,

All of that performance package got your clutch slipping?

Careful spending that baby's college fund already...unless Jaxon will be opening a university! LOL

Good luck! Looks like you have a fun day of wrenching ahead of you.

ac

 

[Karson]

Re: Time for some fun...

Karson,

All of that performance package got your clutch slipping?

Careful spending that baby's college fund already...unless Jaxon will be opening a university! LOL

Good luck! Looks like you have a fun day of wrenching ahead of you.

ac

No slippage, yet. Just hoping for a little stronger pressure compared to the OE diaphragm style. I'll probably forget any clutch pull/feel difference after 50 miles of riding... Be cool to see how long I can rock the stock clutch though - I ride a lot of two up offroad, and while I very much try to keep the RPM's in the right area for the speed to keep me where I need to be, very occasionally that and proper braking falls to the wayside when I'm coming in a little hot on a downhill hairpin with a 2000 foot drop straight ahead.

JohnnyCinco had his clutch burn up out in Colorado, cause unknown if I remember. But if I remember some of the story right, he was riding loaded with gear up some of those gnarly passes. More of an attempt at a little mental insurance than anything...

 

[wtiger]

Re: Time for some fun...

Karson, When i installed my clutch plate, i initially put in the green springs... and ran into some problems with the clutch actually slipping. i opened it up twice making sure i installed everything correctly... long story short: in my package, the green springs, although the heaviest gauge, where the shortest springs... the black were significantly longer... gold in the middle. i pulled the green out, and put the black in, and all was right in the world. No slipping. perhaps i got a bad batch of green springs, i don't know and have not really followed up on it, but fyi...
mark

 

[wtiger]

Re: Time for some fun...

I see you already have this info...
::003::

 

[avc8130]

Re: Time for some fun...

No slippage, yet. Just hoping for a little stronger pressure compared to the OE diaphragm style. I'll probably forget any clutch pull/feel difference after 50 miles of riding... Be cool to see how long I can rock the stock clutch though - I ride a lot of two up offroad, and while I very much try to keep the RPM's in the right area for the speed to keep me where I need to be, very occasionally that and proper braking falls to the wayside when I'm coming in a little hot on a downhill hairpin with a 2000 foot drop straight ahead.

JohnnyCinco had his clutch burn up out in Colorado, cause unknown if I remember. But if I remember some of the story right, he was riding loaded with gear up some of those gnarly passes. More of an attempt at a little mental insurance than anything...

Well, I guess I'll be the clutch tester. I slip my clutch quite often between commuting traffic, riding around a military base, and just general dirt bike habits die hard.

I've never thought that a 150 rear with TCS would be able to force a clutch to slip before either the tire broke loose or the TCS stepped in.

How will you be able to tell if your coil springs have more holding power than the stock diaphragm?

ac

 

[Karson]

Re: Time for some fun...

Got around to installing the clutch plate over lunch and took some photos of the process. Only basic tools are needed. Total time <1 hour.

• 3/8" ratchet
• 3/8" 5mm hex
• 10mm socket
• in/lb Torque Wrench

1) You don't have to drain the oil if the bike's on the centerstand. But, I was due anyway and went ahead with that. Your call...

2) Remove the clutch side cover using your 3/8" ratchet and 5mm external hex socket and try to carefully remove it from the motor. There's an upper and lower dowel pin you want to keep track of, as well as trying to remove the gasket as cleanly as possible from the surfaces. Ignore dirty bike 8)

3) Either take a plastic putty knife and remove any remnants of the old gasket now, or set the cover aside and do it prior to reassembly.

4) Remove the diaphragm plate bolts with your 3/8" ratchet and 10mm socket. They're kind of stuck on, and will crack loose when you first start. No worries, it's fine. However, you might want to be careful when you're pulling the plate off, as the friction plates #1 & #2 wanted to sneak out with it. If they do fall out, try to at least catch what was the outside plate (#1) and which was the inner of the plates (#2). (See below for more pics of what I mean)

5) More info on removing clutch pressure plate and how to orient yourself with friction plate 1 & 2. Service manual makes it clear as mud if it happens. Just FYI.

6) If you need to reinstall the plates. Again, more pics/documentation in the event your friction plates grow legs Probably over dramatizing at this point, but oh well...skip to 7 if you're fine ::008::

7) Don't mean to scare anyone above, in #6, it's really not hard. But, figured I'd address the "what-if" in case someone runs into misaligned friction plate concerns in a pinch. Now, simply select either the gold or black (strongest pressure) springs with the bolts/washers that come in the Barnett kit. Tighten bolts to 5.8 ft lbs or 70 in lbs in a criss cross pattern.

8) Put a new gasket on, make sure your dowel pins are in, then put the side cover back on (you cleaned the old gasket material off, right?)

9) Tighten bolts to 8.7 ft lbs or 104 in lbs in the battern listed on 5-63 in the service manual, or look at #6 here. Pic below is so you can align the O2 sensor wire clips correctly (pretty sure mine are right).

I put in the black springs. My gallon jug of Rotella T6 didn't have enough oil to fill up, barely, so I'll pick some more up in an hour or two an report back what an initial 10 mile in stop and go traffic is like. Probably the easiest way to tell any "feel" differences in a pinch since I can't get out in the boonies anytime soon.

 

[avc8130]

Re: Time for some fun...

"centerstand"...so much more elaborate than the way we used to do it on the dirt bikes. We would swap clutches by just flopping the bike over on the left side in the grass.

Nice writeup.

ac

 

[~TABASCO~]

Re: Time for some fun...

Nice write up Karson ::008::

All fancy and such... Nice mod... Report your thoughts after you get some miles on it.........

 

[hANNAbONE]

Re: Time for some fun...

Thx Karson...

 

[Karson]

Re: Time for some fun...

Thanks guys, kinda ashamed of writing something up with bike that dirty. It never really got "cleaned" since the rally. Oh well, I like it dirty. ::005::

 

[Karson]

Re: Time for some fun...pics inside

Found this little tidbit of info inside the box:

I don't know what the stock diaphragm pressure plate is, but clutch pull is nice & constant throughout the pull of the lever, but only a little more firm. Noticeably firmer, but not like it takes a significant amount of effort that would get annoying.

I'm running 6 of the middle-rated pressure springs, the greens IMO might be a little much, but one could go half and half and play with what works for you. The golds are the "least" of them. Nice to have options, but I like the blacks.

Anyway, off to do family stuff. Morimoto's to follow....

 

[clint64]

Re: Time for some fun...pics inside

Nice write up Karson

 

[avc8130]

Re: Time for some fun...pics inside

I don't know what the stock diaphragm pressure plate is,

Want to do an experiment? We can determine it if you would like.

ac

 

[SpenceS10]

Re: Time for some fun...pics inside

Nice write up Karson! Thanks for the info!!

 

[Ironhand]

Re: Time for some fun...pics inside

Are those Unis from Jaxon? Thought I was on the list for a set... :'(

 

[merchant]

Re: Time for some fun...pics inside

Excellent write up. Too funny - I saw your box of goodies in Jaxon's office last week. Interested to see how the new filters/airbox mod works out.

What's this about a trip to AR? Count me in!

 

[Karson]

Re: Time for some fun...pics inside

Yeah merchant - looking forward to it! One of the reasons I can't do the BigTex rally with you - short on time, long on things to do Sounds like a great time though! I plan on using this thread as my little how-to pictorial for that little box of bad ass, but I might spawn them off into their own threads down the road for ease of finding it if folks would like.

Hope you are doing well. You have your crash bars back from powdercoating?

 

[merchant]

Re: Time for some fun...pics inside

Yup. Had the Jaxon skid plate, pannier ranks and bars all powder coated a metallic gun-metal gray. I never would have believed it (given their bashed up condition), but they turned out looking better than new. They look great! I've been meaning to post up some pics. Will get around to it eventually.

Guess I can stop sending you emails about the rally, huh? We have not talked about it much and thought you might still be considering it. I did the mini-rally this past Saturday. It was tons of fun and I learned a LOT from rally veterans. I took 3rd out of 10 riders (2 of which didn't finish). I guess not bad for the my first time out. I made a couple stupid mistakes when I built my route. Oh well, that's why I did this "pre-season" rally.