EBC clutch kit replacement on 06 AE

I just replaced the clutch on an 06 AE. I just got the bike this year and was having some issues with a jerky starts, especially when cold. There also seemed to be some slippag when I would hit second gear hard so I searched the site and read everything that I could. I did a clutch soak initially and that seemed to help but not with the slippage so I searched out replacement clutch kits. Barnett does list a clutch replacement kit on it's site but I couldn't seem to find one at any of it's sellers so I went with and EBC clutch relpacement from JCmotors, 101.35 with shipping and the replacement spring. I could have probably got away without the spring, $17 but I thought I might as well since it was apart. I thought they might be the Barnett style individual springs but it turned out to be the OEM type ring. When I took the assmbly apart it seemed there was uneven wear on the first and last fiction plate but the metal plates seemed to be in good shape. The replacement kit is a little differnt from the origianal in that all the plates seem to be the same style as the last outer ring on the OEM plate. There are no markings that line up the tab to the basket so I just installed it randomly. I used the posts on here and thanks to everyone that posted thier pictures. I've got a few pics on my camera of the old plates and new ones and will post them when I find my camera cord.

I can honestly say it's solved all the jerky starts when the bike is cold, it is a smooth start now even when the bike cold. I haven't taken it out for a hard ride yet but it seems to be really smooth on the starts and I have no doupt I won't be getting the slippage. I did have some issue's with it not shifing and the "shift" light coming on when I inistially installed it but I went back and did it all again taking special care to make sure the first smaller ring was positioned right with the steal ring in the back of the clutch basket. It does seem to be a little tight, they new plates come right to the edge of the basket, possibly they are a little thicker, at least right now being new. I also made sure I torqued the spring bolts down evenly and using a cross pattern. The first time I turned it on I got the shift light again, but after turning it on and off. (the clutch engages and disingages when the bike it turned on and off) a couple of times that solved itself, I suspect they plates just seat a litttle and there isn't a problem. I also made sure I soaked the cluch 36 hours in oil.

I'm not sure this will help anyone but I thought for $100 a new clutch kit is a easy fix for a an annoying issue that seems to be out there with some AE models.

Good information, even for us non AE folks. My '06 with 47K is still going strong w/o any signs of impending clutch doom. Perhaps AE's are a bit harder on clutches with more initial slipping going on verses us regular *lever* folks.

Thanks for the post.

--G

I hope this solves your problems, BUT...

jerky starts arent what I would call common, but its happened to a few people on this board (myself included...there was a big thread about my adventures with it last year)...Yamaha replaced my entire clutch, and although it alleviated most of the issue, it still raises its ugly head from time to time. So....YMMV.

As far as the clutch slipping, I think its part of the design. My clutch will slip if I WOT also. Its similar to how the AE slips the clutch in first gear if you take off and accelerate slowly.

My bike has 4k miles on it BTW.

If the time comes that my clutch shits the bed I plan to do a clutch spring conversion. https://www.barnettclutches.com/products/spring_conversions.aspx?cat_id=6&prod_id=528

I bought one of these for my old FJ-1200 but never had a chance to install it.

Canadian FJR

Canadian FJR said:

If the time comes that my clutch shits the bed I plan to do a clutch spring conversion. https://www.barnettclutches.com/products/spring_conversions.aspx?cat_id=6&prod_id=528

I bought one of these for my old FJ-1200 but never had a chance to install it.

Canadian FJR

Click to expand...

Well I will be changing out to the Barnett Spring Conversion and their clutch pack soon. I will soak the plates for a day or three and source the gasket when the new stuff shows up.

I believe I need to soak the clutch plates on my 10 so I figured what the hell why not just do it up? Little over 300 to the door for both so we will see how it looks and goes.

Only thing is it seems from the clutch pack breakdown, only 1 disk is different then the rest, where I think two are on the factory clutch pack?

I am looking forward to doing it at my leisure and soaking those plates will not cost any more if they soak for 1 day or 5, while I procrastinate

Good luck on those EBC friction plates.....

If they last as long as EBC brake pads do, you'll be pushing your bike home from the end of your driveway.

:devil:

"Well I will be changing out to the Barnett Spring Conversion and their clutch pack soon. I will soak the plates for a day or three and source the gasket when the new stuff shows up."

Please post some pics once you install this conversion kit.

Canadian FJR

RadioHowie said:

Good luck on those EBC friction plates.....

If they last as long as EBC brake pads do, you'll be pushing your bike home from the end of your driveway.

:devil:

Click to expand...

+1

I really hope you have better luck with EBC friction plates and the #2 eraser inequivalent brake pads they make.

Just a quick updated, it seems it was a failed experiment. I had issues with the clutch pack. It actually got jammed in gear a couple of times when i was riding hard, had to stall it out, jammed in second and wouldn't disengage the clutch, a flashing shift light on the dash and error codes.Turning the bike off and on again reset it and I got it home but not worht the trouble.

I put the original back in, soaked it for about four days and now just have less intense jerky starts but only when it's cold. I may try again in the winter when I can't ride. I'm not the brightest bulb on the chain so I may have messed it up when I put it together but couldn't be wasting any more sunny days messing around with it. The original is working the same, not flawless but I'm riding and the jerky starts are just the first time it engages so I can live wtih it. I'm sure my neighbors think I'm a newbie rider or something but whatever,, see me jerking around when I start off every day. I did find if I shift it into gear hold the brake and rev it so the clutch engages it does help but I usually don't bother and just liver with the little hops and shutters. I can't say I've ever been impressed with EBC in the first place but it wasn't alot of money and I thought I woudl try it. Now it's time to ride and not mess around too much with it.

Quixote said:

...Just a quick updated, it seems it was a failed experiment.

...see me jerking around when I start off every day....

Click to expand...

The other cause of a jerky start on the AE/AS is that the clutch hydraulic fluid needs bleeding. Unfortunately, it's a right POS. My '10 suffers a bit, but only when left for a day or so, perhaps worse when the weather is cold. I thought about getting the dealer to fix it, but you have to dismantle the rear of the bike, I don't want to risk any collateral damage.

mcatrophy said:

Quixote said:

...Just a quick updated, it seems it was a failed experiment.

...see me jerking around when I start off every day....

Click to expand...

The other cause of a jerky start on the AE/AS is that the clutch hydraulic fluid needs bleeding. Unfortunately, it's a right POS. My '10 suffers a bit, but only when left for a day or so, perhaps worse when the weather is cold. I thought about getting the dealer to fix it, but you have to dismantle the rear of the bike, I don't want to risk any collateral damage.

Click to expand...

Crap-in-a-hat, I'd read in similar threads the clutch bleed on an AE is a royal PITA....where the hell IS the bleed nipple? Isn't it on the slave cylinder on the left side of the motor?

RadioHowie said:

mcatrophy said:

Quixote said:

...Just a quick updated, it seems it was a failed experiment.

...see me jerking around when I start off every day....

Click to expand...

The other cause of a jerky start on the AE/AS is that the clutch hydraulic fluid needs bleeding. Unfortunately, it's a right POS. My '10 suffers a bit, but only when left for a day or so, perhaps worse when the weather is cold. I thought about getting the dealer to fix it, but you have to dismantle the rear of the bike, I don't want to risk any collateral damage.

Click to expand...

Crap-in-a-hat, I'd read in similar threads the clutch bleed on an AE is a royal PITA....where the hell IS the bleed nipple? Isn't it on the slave cylinder on the left side of the motor?

Click to expand...

Since you ask, I've put some example pages of the book on my website (if the moderators consider this a breach of copyright, I'll remove them and write a summary), click on the images below for the pages.

EBC is an excellent co. I have nothing but great things to say about there products and service. I have been doing business with them since 98.

I have been using the upgraded "pro" sinistered pad and get about 30,000 miles out of them.

When I need a new clutch I will go with the EBC. I'm sure you will be happy with EBC.

mcatrophy said:

Quixote said:

...Just a quick updated, it seems it was a failed experiment.

...see me jerking around when I start off every day....

Click to expand...

The other cause of a jerky start on the AE/AS is that the clutch hydraulic fluid needs bleeding. Unfortunately, it's a right POS. My '10 suffers a bit, but only when left for a day or so, perhaps worse when the weather is cold. I thought about getting the dealer to fix it, but you have to dismantle the rear of the bike, I don't want to risk any collateral damage.

Click to expand...

Bleeding the clutch on an AE is easy peesy. Get a speed bleeder and go to town. Not very hard at all so I am not sure what you are ascarred of!

03silverbullet said:

EBC is an excellent co. I have nothing but great things to say about there products and service. I have been doing business with them since 98.

I have been using the upgraded "pro" sinistered pad and get about 30,000 miles out of them.

Click to expand...

This your EBC dealer?



Glad you've had good luck with EBC pads. I've installed 2 sets on the front of my '04 and the braking material evaporated in under 10,000 miles, between both sets. They will never darken my door again.