DIY Soft Clutch from a new Bueller

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Jul 13, 2010
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Hello Fellow Buellers,

New here and glad to be a new Firebolt owner. Just to quickly introduce myself and my riding history: I live in the Bay Area California, 1st bike 88' FZ600 (in my 20's), 2nd bike 02' VFR (in my 30's), 3rd bike 08' XB12R (currently in my 40's - getting old but not quite old enough for a cruzer yet). I picked up my Firebolt around 2mos ago and did a little homework before deciding on the 12R, my priorities were TWISTIES, LOW MAINTENANCE and DIFFERENT and the 12R fit the bill. I was aware of the little "CONs" of the Buells but the 12R's uniqueness outweighs them by far. Lurking here on buellxb.com well over a year before picking up the Bolt so I was well informed on what to expect when jumping into riding a Buell. What I didnt think would be a problem was the stock hard clutch, it wasnt a problem my 1st month of ownership because I was just cruzing around getting to learn my new beast. After getting to know this monster I've been hitting up every twisty road in the Bay Area, I'd say in just the past 3 weeks I've done maybe 300mi alone on twisties (I'm talking about XXX Hardcore Twisties). Never have I ever felt any soreness in my left hand from clutching. Last Sunday my buddy hit me up for another 140mi ride, around 60mi of twisties and no pain what so ever. The 12R carves on rails and pretty much does it all on its own, its just amazing. No pain Sunday, no pain Sunday night but then Monday morning I wake up with a big knot on my left hand between the thumb and my pointer finger. I thought what the hell, then it dawned on me and remembered a few Buell riders complaining about the hard clutch pull on these bikes. I still lift weights, play softball and work constantly wrenching handtools so never did I consider it would be a problem after reading about the hard clutch. I guess being over 40 now my body doesnt recover as quickly from being battered. So I do a search for what's the Buell/HD hard clutch fix. All I could find is a Muller Power Clutch ($190) and another add-on devise called a Soft Clutch ($60) made by a European company. I couldnt find the cheaper Soft Clutch offered from any of the US websites and would rather not buy from any Euro sites just cuz I dont like waiting for overseas shipping. I zoomed the online pictures of the Soft Clutch and said to myself "**** I can make that". So I searched around a local Industrial Surplus shop and found a hardened aluminum bracket to modify for this project. The end result seems to feel like the clutch pull needs 30%-40% less effort just like what the Soft Clutch product claims. The only other change in the feel of the clutch is that it engages a tiny bit earlier, no biggie. One concern I have is that I used Hardened Aluminum, I think Stainless Steel would have been my 1st choice but what the heck I only paid $0.50 for the Aluminum part and if it does become a problem I can remove my one-off part then have my machinist cleanup the lines and duplicate it in Stainless :D

I wanted to add photos of this project but cant figure out how to add the images. Can someone tell me how to add photos in this forum. -thnx
 
up top wheren you log in near where it shows your private messages and all there is a link called my pics if you click on the link it takews you to a page where you can browse and upload pics to the forums then when your typing a response or a new post there is an add your photo button below the smiley faces click that it opens a new window and you just click on the pic you want and it posts in in the thread for ya pretty simple and wleocme to the boards and the world of Buells
 
Hey Guys, Here are the SoftClutch Mod pics (thanks strmvt).

Started with a $0.50 bracket made of hardened aluminum
7458_20100713050129_L.jpg


Finished part. Lines arent super clean and coulda prettied it up more but I just wanted to make it with the least amount of cuts. What can you expect with only a drill, hacksaw and a dremel.
7458_20100713050430_L.jpg


Parts assembled together
7458_20100713050511_L.jpg


BEFORE
7458_20100713050606_L.jpg


AFTER
7458_20100713050635_L.jpg
 
[up]

very nice work.. how much softer does it make pulling in the clutch? Also.. what are the specs on the piece.. Thickness (which i assume varies).. length.. distance in between the holes.. etc or if ya jus wanted to make another.. ha

adam
 
Hi atc,

If you look at the original Aluminum piece it has 2 thicknesses, 1/4" and 1/8". I purposely selected this piece so I can leave a solid stop point which you can see hanging off at the top left of the finished part. The stop is to keep it from slipping in case the screw & nut loosen. The nut has nylon at the top of its threads to help prevent the possibility of things coming completely apart, the last thing you want is a loose screw or nut bouncing around in there. The distance between center of each hole is 5/8". The cable adaptor slips on the 1/8" thick part which I found that I needed to sand down a tiny bit to allow the adaptor to swing smoothly. The stainless screw & nut I used are 1/4-20. I believe I can really feel the clutch pull is at least 30% softer. I've already done 4-5hr rides, spots with over 1hr of continuous twisties. I'm sure this mod is going to come in handy for those kind of days.
 
nice work. the only thing that would prevent me from doing this is that you don't get as much disengagement when you pull the lever. Does it lurch any worse than it did before when shifting from N to 1st? This is always more noticeable when everything is cold.
 
Hello brightbuell,

Im not in the motorcycle aftermarket parts business and I'm afraid of liabilities and patent infringements because Im not the originator of the design of this part. I pretty much just copied something I saw on the internet using basic hand tools (google "buell soft clutch"). If I did offer any for "Donations[smirk]" I would rather have it redone in stainless steel so I could sleep at night. I'm really tempted to take my one-off part out and have my machinist make a few in stainless. For now, sorry brightbuell:(
 
konarider,

I've only ridden it for a quick test ride last night, other than the clutch being noticeably softer and the clutch engaging a little sooner when releasing the lever I didnt notice much else that changed. Sure when I first got the bike I noticed how when going from N to 1st goes "klunk", coming from riding Japanese bikes how could I not. I've become accustomed to the klunk and just relate it to the old Sportster motor & tranny, no noticeable difference during the test ride. I'll have to take it out for a good beating for a proper evaluation. I'll post something as soon as I get the chance.
 
OK so I was able to get a good 30min ride thru some twisties yesterday for a proper evaluation. The N to 1st KLUNK is still the same, no worse than before installing the mod. While the bike was still cold I put it into 1st and the usual HD KLUNK was heard and felt. With the clutch still pulled in I didn't feel any lurching or even the slightest feeling of the bike trying to pull away. I even backpeddled the bike backwards on flat level ground for a test and I don't feel any resistance so I think its safe to say the clutch is fully disengaged. Now as for the overall riding experience with this soft clutch mod installed, BUTTER SWEET! I'll have to repeat what others have said after installing a Muller Powerclutch on their XBs "this is how the XBs should have been coming straight off the showroom floor". My opinion is if you're a XB hardcore twisties rider, whether it be a $190 or $60 product or this DIY project, a softer clutch is a must do mod. Along with the Breather Reroute Mod.
 
The Buell clutch levers have way more pull than you need. When I picked up my bike it came with a lever meant to have less reach for smaller hands. It felt normal, but now that I put the stock lever back on I can tell it has so much more pull than it really needs. I'm sure that if you're still using the stock lever you will have more than enough for your clutch to still disengage properly.
 
More riding over the weekend and glad to report my DIY SoftClutch part is holding up well. I'm still using the stock XB levers but now planning on picking up some shorties:D
 
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