Deep Dive into the 2.5 R/GT - valve check/adjust, timing, clutch renewal, fuel and air filter and spark plug change....

Journeyman · Tuesday at 6:20 PM

Video here of the the 20/40K service, including a clutch overhaul. DIY saves you a couple grand, I believe, and the satisfaction in knowing that it's been done right. The bike absolutely runs and shifts better- absolutely. I was surprised just how much better she pulls and shifts- I guess because the loss is so gradual over time, it's hard to notice the difference until it's been corrected. Although the clutch pads were still in spec, there was a groove worn into the steel plate adjacent to the judder ring. I decided to just replace the entire kit. It now doesn't have that stutter on cold mornings and shifts buttery smooth.

Finally, a shout out to @Kevin frazier for his help. I tried to finish up on a weekend when, apparently, my brain was offline- I just had too much personal stuff going on. He helped me off that cliff and I was able to finish up in time for some good riding weather before it turned cold again.

I will say, that I don't think there has ever been a major project I've done since joining this group where I haven't needed to call on the expertise of a member with superior mechanical abilities. There is a wealth of information here and I am grateful.

So, here it is. Jump on in....

Journeyman · Tuesday at 6:21 PM

This is from earlier - more text and photos...

A look at the 2.5 Innards - DIY 20K mile service, including valve clearance check and shim replacement

Part 1 This includes valve clearance check and shim replacement. Also air, fuel, spark plug and coolant replacement, and bleeding the clutch. This is a work in progress, so edits and further information to come... Get the service manual here...

www.r3owners.net

Kevin frazier · Tuesday at 6:40 PM

Journeyman said:
Video here of the the 20/40K service, including a clutch overhaul. DIY saves you a couple grand, I believe, and the satisfaction in knowing that it's been done right. The bike absolutely runs and shifts better- absolutely. I was surprised just how much better she pulls and shifts- I guess because the loss is so gradual over time, it's hard to notice the difference until it's been corrected. Although the clutch pads were still in spec, there was a groove worn into the steel plate adjacent to the judder ring. I decided to just replace the entire kit. It now doesn't have that stutter on cold mornings and shifts buttery smooth.

Finally, a shout out to @Kevin frazier for his help. I tried to finish up on a weekend when, apparently, my brain was offline- I just had too much personal stuff going on. He helped me off that cliff and I was able to finish up in time for some good riding weather before it turned cold again.

I will say, that I don't think there has ever been a major project I've done since joining this group where I haven't needed to call on the expertise of a member with superior mechanical abilities. There is a wealth of information here and I am grateful.

So, here it is. Jump on in....

Awesome job!

imcool · Tuesday at 7:20 PM

Best person ever

rick danger · Wednesday at 5:05 AM

That video is gold. I hope I can remember "deep dive" as search words when its time to do mine. Crazy what has to come off for a clutch bleed with the engine mounted as it is in the Rocket. Great job. Thanks for the effort.

rick danger · Wednesday at 5:23 AM

I just had a thought. Did you happen to pull some clutch fluid directly out of the slave to see what it looked like in comparison to what was in the master? It might have helped to see how much migration of fluid actually goes on. And prove how effective syringing out fluid at the master is for prolonging the time between proper full bleeds.

Journeyman · Wednesday at 7:33 AM

rick danger said:
I just had a thought. Did you happen to pull some clutch fluid directly out of the slave to see what it looked like in comparison to what was in the master? It might have helped to see how much migration of fluid actually goes on. And prove how effective syringing out fluid at the master is for prolonging the time between proper full bleeds.

Hi Rick- I have been pulling up most fluid from the MC on a fairly regular basis, as I seemed to have a very small air-in leak (no fluid drop). I'd top off with fresh DOT 4 and bleed the MC to restore function (smoother shifts). So, on my bike over time the fluid was already essentially flushed- I still did a full bleed this time. I tightened up the banjo bolt at the slave and MC and think/hope that has sealed the leak. To answer you question though, I have read debate over whether or not the fluid actually circulates. I was convinced that it does, but doing what you suggested would have settled that for certain.

rick danger said:
That video is gold. I hope I can remember "deep dive" as search words when its time to do mine. Crazy what has to come off for a clutch bleed with the engine mounted as it is in the Rocket. Great job. Thanks for the effort.

Thanks! Yeah, I have to say of all the steps dealing with the radiator is my least favorite part, by far. It's probably why I put this off several thousand miles past the 40k mile maintenance interval.

One small tip randomly comes to mind. Take a sharpie and make a nice fat alignment mark where the top hose meets the pipe on the bike. The bend in the hose, as well as which end goes up/down is important in getting the radiator lined up properly.

mo8414 · Wednesday at 7:06 PM

Good point on the alignment of the radiator hose, thats something most people wouldn't even think of doing. Could stick some sye in the mastercylinder and pump it for a few days here n there then do the flush, that would solve that mystery.

It is amazing how fast the clutch fluid gets dirty, i got 4000 miles on my bike and have had to suck it out and replace the fluid twice now. Will probably be a couple more years before I hit 20,000 mikes and have to mess with it. By then I should have a lift which will make life easier.

This is why I like forums, there are always people in them that know the bike inside and out. I guess for now ill just slowly gather the special tools. Again, great videos and contributions to the forum Journeyman.

Deep Dive into the 2.5 R/GT - valve check/adjust, timing, clutch renewal, fuel and air filter and spark plug change....

Journeyman

"And this one is just right" ~ Goldilocks

Journeyman

"And this one is just right" ~ Goldilocks

A look at the 2.5 Innards - DIY 20K mile service, including valve clearance check and shim replacement

Kevin frazier

Widowmaker!

imcool

Turbocharged

rick danger

Turbocharged

rick danger

Turbocharged

Journeyman

"And this one is just right" ~ Goldilocks

mo8414

Supercharged

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