Air-cooled engines from this era are really something special, aren’t they? The people who created designs that are still loved after all these years deserve real credit.
It’s helpful when OEM options exist. Well, they’re standard parts, but tracking them down is a hassle. I found the perfect one from the press-fit collar box, and it goes in with just hand pressure. Generally, oil seals will go in by hand if the mating surface is fine. I completely degrease the clutch cover surface. A thin coat of liquid gasket around the perimeter as a retention aid is a good idea. It’s completely different now… Small steps, one at a time… that’s how you accumulate love in a hobby bike. I removed the questionable black finish too. It looks better than new. This was very dirty too, so I cleaned it up. (I’m not showing the ugly before picture.) So it’s not a lock nut—it uses a wave washer for tension? That’s a bit questionable for reliability… The countershaft diameter is also smaller, so compared to oil-cooled, the torque spec is gentler—easier on humans too. The clutch holder is Suzuki OEM, but if you make various attachment brackets, you can do whatever you want. Done! The prep work is finished, so I picked it up the other day. PAMS Single / Complete Clutch Kit The packaging is fantastic. No issues, but off-the-shelf stuff like Advantage FCC comes in vinyl bags. I was impressed, but I had to inspect it anyway.
New Friction Plate Old Friction Plate
New Steel Plate Old Steel Plate
At this point I had a moment of “Huh?”
Hold on—let me multiply by seven-tenths, eight-tenths, and check the total thickness… bingo! Of course—I was overthinking it.
① The gentlest clutch—light and soft. * The washer bottoms on the sleeve, so there’s no initial tension. ③ No retainer. Heavy is fine, but we can’t have it slipping—that’s the racing spec, so… ② Slightly plus. Without the washer, there’s initial tension.
Naturally, I went with sweet and mild—option ①.
It’s like reducing the area per plate to increase contact pressure. The friction material is modern too, so there’s nothing to worry about. That’s how I assembled it. * It’s not a huge job, but… ● it does take time (with all the cleaning). I replaced all the bolts with electroless nickel (iron) too. The window looks clean and nice. I was curious, so I did this one too. Cleaned it up. And that’s it—all done. It looks great and feels fresh. Tomorrow’s supposed to be heavy rain? I hate that lately.
