H2 / H1 Lockup Race Clutch

Product 11_74 / 11_79 Installation

Ralf Schipmann Stand 20. Januar 2017

2

1. Your parts ............................................................................................................................... 3 2. Installation .............................................................................................................................. 4

Hub ......................................................................................................................................... 4 Center nut ............................................................................................................................... 5 H1 special nut ......................................................................................................................... 6

3. Install plates. ........................................................................................................................... 7 No expansion rings ................................................................................................................. 7

Friction plate preparation ....................................................................................................... 7 H1 ........................................................................................................................................... 7 H2 ........................................................................................................................................... 8

Bearing mushroom ............................................................................................................... 10 Pressureplate ......................................................................................................................... 11 Springs .................................................................................................................................. 11 Lockup plate ......................................................................................................................... 12

Final check ........................................................................................................................... 13 4. Adjust actuator and cable .................................................................................................... 14 5. Install clutch cover. .............................................................................................................. 16 6. H1 rare transmission input shaft (very early H1 ??) ............................................................ 17

7. Exploded view ...................................................................................................................... 19

3

1. Your parts

Figure 1 (H2 kit)

Figure 2 (H1 kit)

4

2. Installation

Figure 3 (engine ready to take new clutch)

Hub

Put hub on inputshaft and add the new washer that came with your kit. Do not use the stock

"toothed washers".

Figure 4 (install hub and new washer)

5

Center nut

Install center nut. Use liquid thread locker to make sure nut won´t ever come loose.

(LOCTITE 243 or similar)

Figure 5 (center nut - use liquid thread locker)

Tighten nut the same way you do on stock clutches.

Figure 6 (tighten nut)

Attention:

H2 uses stock nut.

H1 requires the special nut that came with your kit.

6

H1 special nut

Figure 7 (special nut for H1)

Take care you install nut right way round.

Figure 8 (install special nut - H1 only)

7

3. Install plates.

No expansion rings

The lockup clutch works without expansion rings.

Figure 9 (do not add stock expansion rings)

Friction plate preparation There is no special procedure (like bath them in oil for a day) required. Get your kit out of the

box, install on bike and ready to go.

H1 H1 kit contains 7 steel and 7 friction plates (all friction plates are equal).

Start with a friction plate, next is a steel plate, then a friction plate again and so on until all

plates are installed.

Note: The last plate is a steel plate!

8

H2 H2 kit contains

8 steel plates

6 long ear friction plates

2 short ear friction plates

Figure 10 (long and short ear friction plates - H2 only)

Start with a "long ear" friction plate, next is a steel plate..... Add 5 "long ear" friction plates

and 5 steel plates total this way.

Figure 11 (5 "long ear" friction plates and 5 steel plates installed on H2)

9

Continue now using the 2 "short ear" friction plates.

Add the stock support ring.

Figure 12 (2 "short ear" friction plates required because of support ring on H2 )

Finally install the last friction plate which is "long ear". Put steel plate on top.

Note: The last plate is a steel plate!

Figure 13 (all plates installed)

10

Bearing mushroom

Next add bearing mushroom.

H2 kit contains a ball bearing type

H1kit contains a needle bearing type

The bearing mushroom allows you to pull clutch for a long time without risk of damage. This

is important in particular if you go on a dyno.

Figure 14 (add bearing mushroom )

Please note:

H1 has no ball in between pushrod - So does H1 lockup clutch (H1 no ball)

H2 has a ball in between pushrod - ball remains there. (H2 with ball)

Do not forget the ball, don´t add 2 balls.

11

Pressureplate

Now add pressureplate.

Figure 15 (pressureplate in place )

Springs

Next add the springs that came with your kit.

These springs are special designed to work with the lockup clutch. They allow you to pull

clutch with 2 fingers and still face no slipping under heavy load.

H2 version has been tested beyond 150 hp (!!!) and definitive doesn´t slip.

Do not try install stock springs. They won´t fit and won´t work.

Figure 16 (special springs installed)

12

Lockup plate

Now add lockup plate and M6 x 25 countersunk screws.

Figure 17 (lockup plate and its countersunk screws )

Important: Tighten screws by hand and sequentally (like installing a head) to allow the

lockup plate dive freely into the pressure plate without binding.

Warning: Do not use air or electric driven wrench. It will

damage your parts.

Figure 18 (lockup plate installed)

13

Final check

If you now see the planar faces of lockup plate and pressure plate are roughly at same level

(figure 19) everything is fine.

If you don´t something is wrong. Check cable and actuator adjustment (see chapter 4). Also

make sure you have not forgotten a plate or added a wrong plate (from the stock clutch for

instance). If in doubt take all plates out and check what´s wrong.

Do not ignore if something is wrong. Clutch will take massive engine hp and last for a

long time but is sensitive to wrong installation.

Figure 19 (lockup plate installed - check level)

14

4. Adjust actuator and cable

The lockup clutch works with all versions of stock actuators (plastic, steel/plastic, ball

bearing) and also with the aftermarket ones (known as "Hawaii" or "Black Forrest actuator")

Latest versions of kit (January 2017 onwards) feature a mushroom with a slot. If you have got

an older version you may add a slot by hand with a saw. 1-1.5 mm deep is fine. Just make it

for a small screwdriver to fit in.

Figure 20 (slotted mushroom)

Adjusting starts with untighten the locknut from actuator adjuster screw. Turn out screw a few

turns so there is definitive a gap between mushroom and pressure plate.

Next adjust cable so the actuators lever is roughly at 8 o´clock position. (see figure 21)

Figure 21 (lever in 8 o´clock position)

15

Now slowly turn in the actuator adjustment screw while you continuously turn the mushroom

via screwdriver.

At first mushroom will turn very easy as its free (should have a gap towards pressureplate).

As you further turn in adjustment screw at one point you will feel resistance starts while

turning the mushroom.. That´s the point when there is no more gap between mushroom and

pressureplate.

From this point turn actuator adjustment screw out ca. 1/2 turn.

Tighten actuator adjustment screws locking nut.

Check again if mushroom turns resistance free. Repeat procedure if it doesn´t.

Figure 22 (actuator adjustment screw) Figure 23 (turn mushroom with a screwdriver)

Check settings careful. If clutch slips on first testride it´s a common mistake

that cable or actuator are set up wrong (no gap, disengages the clutch

"a little" all the time).

16

5. Install clutch cover.

The unique advantage of this lockup clutch is that it fits under stock cover. But all space

available in there is needed.

This means you must

use a paper gasket for clutch cover. Otherwise you loose at least 0.5 mm height.

use a stock non damaged cover. A welded up cover (such as repaired after an accident)

might not fit.

in some rare cases (depending on tolerances of cover) we have seen that the "cross"

(from casting process) must be grinded off in area where lockup plate levers rotate.

This is an area between diameter 40 mm and 85 mm. (see the 4 "hatched islands" in

figure 23) So far this has come up on H1 only.

In any case check if the clutch turns free when clutch cover is in place BEFORE you

tighten all bolts and have filled up oil.

Figure 24 (partly remove casted cross if required)

17

6. H1 rare transmission input shaft (very early H1 ??) Some H1 have a rare slightly different input shaft. Not sure but I think it´s very early 69

transmissions only.

These shafts can be identified easy as they have a "hollowed end".

Figure 25 Figure 26 (shaft with hollow end on some H1)

(usual shaft end on most H1 and all H2)

18

These rare shafts have a thread that is about 2 mm longer. (Figure 27 left shaft)

Or in other words: the shaft is about 2 mm longer.

Figure 27 (thread about 2 mm longer on some rare H1 input shafts)

To install lockup clutch on this type inputshaft the thread MUST be shortened by 2 - 2.5

mm.

A good craftsman can do this (without splitting cases / disassembling transmission) by hand

with an angle grinder and a thin cutting disk.

19

7. Exploded view

Figure 28 (exploded view H2 version)