Installing Dave Dodge's High Performance Kevlar Clutch


Installing Stainless Steel Clutch Lines

Since I was already in the process of installing a Kevlar Clutch Kit , I figured I might as well replace my stock hydaulic lines with stainless steel lines.  It is probably even more important to switch to stainless steel lines on the brake lines, but that will be saved for another day. clutchkit_tn.jpg (20935 bytes) The kit itself simply consists of a single line and two sets of crush washers.  Replacing the lines is a pretty simple task, the most important point to remember is to keep the bike covered so fluid won't drip on any painted surfaces.coverbike_tn.jpg (37230 bytes)  In my case, I simply spread a large plastic garbage bag over the tank and moved it around as needed to keep everything protected.

The first step is to remove the clutch line from the slave on the left side of the bike.  This is accessed by removing the small plastic cover.  Disconnect the end of the stock line and let it drain into a container.  Pumping the hand lever will force out more of the old fluid and then take off the cover on the master cylinder and pump some more.  With most of the old out, disconnect the line from the master (your bike is covered at this point, isn't it?).

With most of the old fluid out, it is time to remove the old stock line.  I had hoped to pull this line out as a single unit and keep it for emergency future use.   However, I found the only way to remove it was through the use of a precision extraction tool.  With the old line out, simply snake the new stainless steel line through, following the same basic path the old line followed.  I started from the front and it went in fairly easily.  The next three pictures show the slave cylinder with the stock line disconnected, but not removed, and the new lines attached to the slave and master cylinder, but not dressed yet.

Slave SS lines on masterSS lines on slave

Since I was on the clutch hydaulic system, I decided to also replace the bleeder valve with a SpeedBleeder.  I had heard the horror stories some people had reported of trying to bleed the system and was nervous about getting all of the air out.  Bleeding the system, however, turned out to be a simple task.  I started by following the directions and opening the SpeedBleeder a 1/2 turn and start pumping, mityvac_tn.jpg (32301 bytes)but soon realized that this was going to take all day since my system was entirely empty of fluid.   I fixed that by hooking up my MityVac to the bleeder valve and pumping up a good vaccum.  Closing the clutch lever at that point had fluid though the system in nothing flat.  Since I wasn't sure when the last time this system had been flushed, I did that a couple times, pumping a lot of fluid through the system.  I finished it by removing the MityVac and replacing with the hose into the overflow container.  A few more cycles of pumping the lever with the SpeedBleeder 1/2 turn open gave me a nice solid clutch feel.