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Thread: How to install Hydraulic clutch

  1. #1
    Very Active Member Rainey5230's Avatar
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    Default How to install Hydraulic clutch

    Remove engine side cover and loosen cable nuts , 12mm

    loosen bracket bolt 10mm

    uninstall clutch cable and make wire for it


    pull the old clutch cable make wire follow it
    Then hook new oil hose up
    if you use riser extension under 2"
    Please don't follow old way, Don't cross the motor mount
    by-pass it and go the engine case bottom
    Our oil hose is 155cm , it can fit stock length and 1" riser extension

    ATT this holder , cross it.

    make sure this posittion

    remove the bar end chrome cover and uninstall grip with glass clearner

    remove 2 bottom bolts

    ready to remove stock lever with mount






    this is new lever use bolt , add butter oil

    install lever with master cylinder
    Don't forget put the brass ball in it

    insert the bolt in lever

    tighten the 10mm nut
    and install the lever switch(ignition)

    install the master cylinder in handle bar
    fit the old position

    the bar bottom have a hole, this is switch assy check point.

    install the grip back

    install the bolt and washers with oil hose connector

    tighten them 13mm and 14mm tools

    remove the swingarm bolt 10mm

    maybe you have to use hammer to push the swingarm out.

    check the swingarm head to fit slave cylinder head

    make sure swingarm could be swing very smooth

    remove the shaft swingarm 10mm bolt and make a sign for it.
    when you install it back use, you can setting in correct position.

    remove it

    remove those 2 bolts , 8mm
    you got install slave bracket it back in 10 mins.
    because the oil will be leaking

    when you install swingarm back, it have a check point.
    you must make it in correct position.
    This is hard to install it back, you need screwdriver help you for it.
    then pull the spring to hook swingarm.

    tighten the slave cylinder top nuts 13mm

    How to drain air out hydrualic, Please follow the user manual or ask other member.
    use the compressior can be help you easy install and save a lot time.

    This is a small "star" winch for drining air.
    after all air is drained, tighten it and use water clean this part

    use the cable tie for oil hose position.
    Don't let the shaft linker hit it.

    tighten the bolt 8mm back and mounting the cable in old location.

    inspect all detail and make sure all bolts and nuts tighted

    You can try this way for make your handle bar more clean

    pull the harness switch connector pins out

    there are 2 pins from stock harness side

    New switch have 3 pins jump the middle
    only use front and rear

    finished

    use the 3M BUTYL WINDSCREEN SEALANT for waterproof

    Check it working then install side cover back




    http://www.youtube.com/my_videos_annotate?v=0HOxsFfaSxo

    Last edited by Rainey5230; 05-05-2012 at 02:51 PM.

  2. #2
    Very Active Member freddo62's Avatar
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    very nice RAINEY!!!

  3. #3
    Very Active Member Rainey5230's Avatar
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    Quote Originally Posted by freddo62 View Post
    very nice RAINEY!!!
    Sorry My english bad if buddy have any questions . Please ask old members.

    Original size pics













































    Last edited by Rainey5230; 04-18-2012 at 02:55 PM.

  4. #4
    Radio Active Member rynosback's Avatar
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    I would dremel this and not pry it. I state this from experience, as the part is cast. But a very nice right up.

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    Bang for the Buck Mods link CLICK HERE
    2013 Mid Atlantic Meet CLICK HERE

  5. #5
    Very Active Member Rainey5230's Avatar
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    Quote Originally Posted by rynosback View Post
    I would dremel this and not pry it. I state this from experience, as the part is cast. But a very nice right up.

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    yeah but this steel is soft not really hard.Rasp it will be better.
    I mod 6 bikes here. some 9R is easy to install but some bikes need tuning it.
    Last edited by Rainey5230; 04-18-2012 at 03:47 PM.

  6. #6
    Very Active Member BigpapaM109's Avatar
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    Quote Originally Posted by rynosback View Post
    I would dremel this and not pry it. I state this from experience, as the part is cast. But a very nice right up.

    Click image for larger version. 

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    I have pryed everyone I have ever done with no issues. Just have to do a little at a time.

  7. #7
    Very Active Member rudeboy109's Avatar
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    Great write up, only one thing left out......buying the Hydraulic clutch... when, where, how much, ect.
    08,M109R2[250 Dunnie, PC3, stebel air horn, K&Ns, flame mirrors, debaged, gutted pipes, suzuki engine guards, piaa hyperwhite headlight, back off modulator, gipro atre, front motor mounts, debeavered, Kuryakyn Iso Grips, Factory Pro star kit, G-Man shifter bushing, Guardian Bell, Catch can mod....... more to come

  8. #8
    Very Active Member WhiteStar's Avatar
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    ... definitely interested



    Quote Originally Posted by rudeboy109 View Post
    Great write up, only one thing left out......buying the Hydraulic clutch... when, where, how much, ect.
    "Don't worry about it rider"

    That one Man is the secret theme of the entire revelation of God to man through that which is known as the HOLY BIBLE... JESUS CHRIST.

  9. #9
    Very Active Member The HUFF's Avatar
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    Amazing work as usual Rainey!

    The trouble with our liberal friends is not that they are ignorant. It's just that they know so much that isn't so. -- Ronald Reagan
    With Individual Freedom and Individual Salvation comes Individual Accountability. It brings a rewarding life to all. <--The Huff

  10. #10
    Very Active Member Rainey5230's Avatar
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    ASSY have 2 kind

    one is fit stock length to 1" riser extension.

    http://cgi.ebay.com/ws/eBayISAPI.dll...ht_1060wt_1054


    2" - 3"

    http://cgi.ebay.com/ws/eBayISAPI.dll...ht_1082wt_1054

  11. #11
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    Quote Originally Posted by Rainey5230 View Post
    ASSY have 2 kind

    one is fit stock length to 1" riser extension.

    http://cgi.ebay.com/ws/eBayISAPI.dll...ht_1060wt_1054


    2" - 3"

    http://cgi.ebay.com/ws/eBayISAPI.dll...ht_1082wt_1054
    So it's $199.00 for just the cylinder. We would have to order the these three parts.
    Cutch Mater Cylinder ASSY: 59800-10F20
    Clutch Lever ASSY: 57500-10F10
    SWITCH ASSY: 57560-10F00

    Is that correct?

  12. #12
    Very Active Member Rainey5230's Avatar
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    Quote Originally Posted by REDSTORM View Post
    So it's $199.00 for just the cylinder. We would have to order the these three parts.
    Cutch Mater Cylinder ASSY: 59800-10F20
    Clutch Lever ASSY: 57500-10F10
    SWITCH ASSY: 57560-10F00
    Is that correct?
    Yes. Correct.
    Our Slave Cylinder Assy including Cylinder/Oil hose(Italy made)/bracket/bolt with washers.

  13. #13
    Very Active Member Rainey5230's Avatar
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    ATT: This Suzuki C90 master cylinder painted is same with VZR1800 '09-On brake master cylinder.
    If your bike is 06-08 , the paint color is a little different with right side brake master cylinder.
    but Their master cylinder cap is same. you can order M109R master chrome cap exhchange it.

    Last edited by Rainey5230; 04-24-2012 at 03:02 PM.

  14. #14
    Very Active Member Deester's Avatar
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    Do the custom levers fit on the left side? Nice idea though!


    Sent from my iPhone using Tapatalk

  15. #15
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    What is the switch assembly for?
    I thought that was for the brake light
    ya would'nt need that on clutch side
    would ya

  16. #16
    Very Active Member erbemone's Avatar
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    Safety switch for starting. Pull clutch in, start bike.

  17. #17
    Very Active Member Rainey5230's Avatar
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    Quote Originally Posted by Deester View Post
    Do the custom levers fit on the left side? Nice idea though!
    Sent from my iPhone using Tapatalk
    Hi

    Only one way is search suzuki C90 ('08 model year) custom lever.
    C90 left and right side lever can be install in this case.

  18. #18
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    Quote Originally Posted by erbemone View Post
    Safety switch for starting. Pull clutch in, start bike.
    Whoops forgot about that must of been brain dead yesterday.
    thanks man............

  19. #19
    Very Active Member Nashty's Avatar
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    What is total cost for everything required as listed below? Can we order everything from you?

    So it's $199.00 for just the cylinder. We would have to order the these three parts.
    Cutch Mater Cylinder ASSY: 59800-10F20 cost?
    Clutch Lever ASSY: 57500-10F10 cost?
    SWITCH ASSY: 57560-10F00 cost?
    Last edited by Nashty; 04-28-2012 at 07:17 AM.
    06 Black 9\De-Badged\De-Beavered\Kuryakyn ISO Grips\GI-Pro\Stebel Air-horn\Shift Kit-EVO-S93\Motolights\Kriss Industries Headlight Modulator\Kriss Industries BLT (Break Light\Turn-Signal Flasher)\Kuryakyn Dually ISO Pegs\KewlMetal 2" Chrome Hole Risers\Cycle House Levers and Kickstand\Suzuki Engine Guards\SS-Brake-Throttle Cables\K&N Filters\Cobra Swept Exhaust\Thunder Monster Baffles\Stock Chrome Wheels\Front Gaffler Rotors\Kuryakyn 2320s wLED bulbs\Cobra PowrPro\

  20. #20
    Very Active Member Rainey5230's Avatar
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    Quote Originally Posted by Nashty View Post
    What is total cost for everything required as listed below? Can we order everything from you?

    So it's $199.00 for just the cylinder. We would have to order the these three parts.
    Cutch Mater Cylinder ASSY: 59800-10F20 cost?
    Clutch Lever ASSY: 57500-10F10 cost?
    SWITCH ASSY: 57560-10F00 cost?
    Cutch Mater Cylinder ASSY: 59800-10F20
    Clutch Lever ASSY: 57500-10F10
    SWITCH ASSY: 57560-10F00

    I bought those 3 item is same with everybody from US. and I don't have any discount.
    those 3 item cost about USD220.0 , but after add international shipping then return to US.
    The cost is too high. My location is in Taiwan.

  21. #21
    Very Active Member bryan67's Avatar
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    Default will do soon

    just waiting for my Rivco risers and tach. relocator kit. Will add this kit to my wish list for later this summer. have to work a few OT days to get the funds But will Definitly be ordering the kit for 2-3 riser soon. Real nice How to also. Great job Rainey!!!!!!!!!

  22. #22
    Very Active Member Rainey5230's Avatar
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    Last edited by Rainey5230; 05-05-2012 at 02:52 PM.

  23. #23

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    I'll just take this set up please. Thank you
    Quote Originally Posted by Rainey5230 View Post
    ATT: This Suzuki C90 master cylinder painted is same with VZR1800 '09-On brake master cylinder.
    If your bike is 06-08 , the paint color is a little different with right side brake master cylinder.
    but Their master cylinder cap is same. you can order M109R master chrome cap exhchange it.


  24. #24
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    Has anyone tried this besides Rainey....thoughts...feedback?

  25. #25
    Very Active Member lostrider's Avatar
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    Quote Originally Posted by peregrine View Post
    Has anyone tried this besides Rainey....thoughts...feedback?

    Dizzy spell has it installed dave.

    http://www.m109riders.com/forums/sho...=140875&page=4
    Last edited by lostrider; 07-25-2012 at 08:10 PM.

  26. #26
    Very Active Member Latinrascal's Avatar
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    Nice video Rainy, this is definitely on my mods to do list, thanks for posting. Can I also make a few suggestions that may help in the future. First by good practice it is recommend to cover the paint when working with brake fluid. A little inadvertent drop will ruin your day pretty quickly on this paint! And when pulling the cable you should pull from the top down so that you don't scuff the show finish of the upper exposed portion of the cable/hose. Just thinking out loud I guess
    Last edited by Latinrascal; 03-12-2013 at 01:14 AM.

  27. #27
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    Quote Originally Posted by lostrider View Post

    Thanks, I will look into this when mine gets older.

  28. #28
    Very Active Member Rainey5230's Avatar
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    Default RE-Design rod connector

    We re-design the slave cylinder rod connector.
    Then you don't need remove release arm when you install this kit.
    After you finished all upper staff(master cylinder , lever ,switch, Please check this post history)
    We suggest go to motorcycle shop that doing this kit install.

    1.
    Check the cable and slave cylinder best angle.
    Then Tighten hydraulic cable connector

    2.Drain air out


    3.Use the wrench turn the release arm down and install the pin to connector.
    PS. This space is very small. You may need other people help you keep turn the wrench.


    4.Tighten the bracket bolts


    5.Install clip R pin.


    6.Push down release arm by hand and adjust slave cylinder position(up or down).


    7. Drain air again and tighten all bolts. Then use water clean all you did.

    8.After check slave cylinder is vertical then use cable tie clamp hydraulic cable on frame.


    Last edited by Rainey5230; 10-31-2012 at 01:56 PM.

  29. #29
    Very Active Member freddo62's Avatar
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    Click image for larger version. 

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ID:	76719I have the first model, do you sell the modified part only??
    Last edited by freddo62; 10-31-2012 at 05:29 PM.

  30. #30
    Very Active Member RUBZERK's Avatar
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    Angry

    just finished installing mine but now i have a problem.

    after i bleed the system my lever will not compress. the shaft on the slave cylinder stays in. if i open the bleeder screw the lever will compress and the slave shaft will release. once i tighten the bleeder screw i am able to compress the lever once but then it will not compress again and the slave shaft stays in.

    what am i doing wrong ?


    "You cant argue with my 9mm..........well you can, but you'll end up bleeding alot"
    BUILT, NOT BOUGHT RUBZERK = Are You BZERK

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