Ian's '86 zl900

I

ian

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I figured I'd start a project thread cause I'm not gonna leave this rocket alone. I've put a stage 3 kit on it that consists of pods, new jetting, and 4 degrees of timing advance. A couple days ago my clutch started not working so I pulled the cover off to find a broken star spring lodged in the pressure plate. While I was researching what to do about it I came accross the "clear clutch cover mod". Today I decided to do the "clear clutch cover" mod. It basically consists of cutting out the clutch cover and replacing it with lexan. I also made a pimp trim ring out of the aluminum that I cut out of it. It's currently just stuck together with window sealant. I was originally gonna use socket head machine screws but it looks so clean I need to fine an adhesive that'll glue aluminum to lexan permanantly and be impervious to oil and gas. I'm open for suggestion. Took me 4 hours of nit picking.

Pic of the broke spring. You can see only 3 out of six fingers left. Not good.

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Pieces of fingers stuck in pressure plate. Thankfully they stayed put and did not end up a fist full of sand in my gear box's vagina.

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pic of cover before I start molesting it.


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Pieces of the cover. As you can see, I need to cut a circle in the main cover. Hole saw !!

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Hole

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Hand filed a bevel on my trim piece and one to match on the lexan.

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Final four pieces.

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Assembled pics


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PS....I'm putting led's in there.

-Ian
 
That's gonna look good.

I was not aware that the center polished piece (shown in pic "pieces of the cover") was a separate piece - what holds it on?

You're going to use adhesive to hold everything together?
 
I'm loving the way it looks. Yeah there's just one clip in the center you take off from the inside of the clutch cover to get the polished circle off. I'd love to glue it with something so it looks clean. But I'm not sure what I'd trust to do the job. There's gotta be something that'd work.
 
ian said:
I'd love to glue it with something so it looks clean. But I'm not sure what I'd trust to do the job. There's gotta be something that'd work.
Click to expand...

Yeah, that would ruin your day if it came off while riding.

Maybe JBWeld or some other epoxy.
 
Good work on the cover. I and at least one other - I believe Bacchus - have done that mod. I have not put mine on yet to try it out yet. I like the polished ring idea. Search on this site and you will find a thread about it. Later.
 
Yeah I read that thread. Anyone care to speculate what a guy could trust to permenantly glue this together?
 
Looks Great! Wish I trusted myself enough to try it. I would say definately some kind of 2 part epoxy.
 
Ian, is that polished circle SOLID all the way through?
 
Ian, This stuff looks good for you, but I'm not sure if you need clear. It says it dries deep red if NOT heat cured, gold if heat cured.
 
MikeC said:
Ian, This stuff looks good for you, but I'm not sure if you need clear. It says it dries deep red if NOT heat cured, gold if heat cured.
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What stuff? I dont need clear cause the adhesive will be behind the trim piece
 
MikeC said:
Sorry, I meant is just a metal piece or is it mounted on plastic?
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The lexan is sandwiched between the trim ring and the lip of the case. So I'll be glueing the lexan to the case then glueing the trim on top of the lexan, clamping it, and heating it from behind.
 
Your doing a nice job!

On my KZ i used a two part epoxy to close off some flap openings on the choke plates. Its been a couple of years now!
 
A 2 part setup is best because they withstand a lot more heat and a chemical reaction is stronger than something drying. 3m makes something i think called formula 46 that i have used to put a pair of boots on a 2 by 4 and hang from them. You will have to get it from an industrial supply place and its not cheap but they do have some different degrees. Give that a look into but i would not trust any one part system to hold something as crucial as that on. And dont forget to scuff the plastic a little to increase the holding power.
 
fatam05 said:
A 2 part setup is best because they withstand a lot more heat and a chemical reaction is stronger than something drying. 3m makes something i think called formula 46 that i have used to put a pair of boots on a 2 by 4 and hang from them. You will have to get it from an industrial supply place and its not cheap but they do have some different degrees. Give that a look into but i would not trust any one part system to hold something as crucial as that on. And dont forget to scuff the plastic a little to increase the holding power.
Click to expand...

Yeah I'll definatly scuff both surfaces. I just want something I don't have to even think about failing. I really don't want to screw it on because it looks so clean the way it is. I think it looks classy right now.
 
check out some of that 3m stuff. I saw that other red stuff had to be heat treated and you definately dont want to have to do that with the plastic. The 3m stuff needs no heat but it will need a while to set up.However, after its entirely set, it is as strong if not stronger than a weld. Let me do some research and ill try to get a link for you.
 
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