GasGas Pro clutch tuning
Many GasGas Pro owners experience clutch drag. The GasGas Pro clutch is very sensitive to the 'finger height' and the currently available complete clutch pack is too thick resulting in noticeable drag - the slave cylinder 'top hat' can't engage the 'shallower' finger height to hold tension or complete disengage. If a 2.00mm steel plate is replaced with a 1.30mm-1.50mm steel plate, the finger height will be too high resulting in slip - top hat stays engaged.
The GasGas Pro uses a Diaphragm clutch design similar to an automobile, and different from mainstream motorcycle wet clutch design.
I recently replaced my Pro clutch pack and discovered the following:
GasGas only sells the complete clutch pack MT280232055 : 3 Friction plates MT280232051 and 2 steel plates.MT280232050 . See note below..
Each steel plate in the complete clutch pack is 2.00mm thick.
2002-2003 clutch packs were different MT280432055 . Early 2002 friction plates MT280232051 were prone to swelling; current friction plates do not swell in ATF.
The 1.50mm MT280232050 , 1.40mm MT280232050/4 , and 1.30mm MT280232050/3 steel plates are no longer available. If used with the current clutch pack to replace one of the 2.00mm steel plates, the overall thickness will be too thin.
If, post 2006 model, both steel plates measure 2.00mm and the friction plates vary in thickness: one friction plate is 2.20mm and the other two 1.80-1.85mm for a overall thickness of 10.00mm? ( I realize the math doesn't add up from the factory specs)
AND
The correct specification is: No less than 9.75mm and not more than 10.05mm
How do we build a clutch pack that measures 9.75mm +/- 0.1mm to acheive the desired 17mm +/-1mm 'finger' to inner hub depth?
I ended up going through all my old friction discs to build the appropriate clutch pack.
I had trouble reverse bleeding the clutch and discovered one of the two orifices in my AJP master cylinder (small reservoir) was blocked. I couldn't clear the blockage; so I replaced the master. I discovered that the master cylinder bore and stroke was relatively the same between the AJP long and short reservoir styles.
Replaced the O-rings in the slave cylinder for good measure. The GasGas Pro Technical Bulletin (10/2006) updated 10/2012
http://www.trialspar...ober_2_2012.doc recommended conversion from DOT4 to mineral oil. We since converted back to DOT5 by replacing the slave cylinder O-rings with MT280432047..
We found the Carquest part number CTC407008 for Viton® O-rings for the slave cylinder a bit tighter than the OEM MT280432047
Note:
2006 and newer model Installation note: The clutch fiber and steel discs were changed in the 2006 model year. The three fiber discs have a variation in thickness and the two steel discs are thicker than the previous models. There may be slight variations in thickness of the fiber discs, this is done at the point of manufacture to ensure precise total pack width. The total pack width is 10.0~10.01mm – The two steel discs measure 2.0mm each – Two of the fiber discs measure approximately 1.80~1.85mm thick and the third one is 2.2mm thick. All steel and fiber discs are symmetrical (there is no specific front or back side)
IMPORTANT: Of the three fiber clutch plates, one is noticeably thicker. (about 2.2mm thick) This thickest plate MUST be the one that is placed into the engine first. (Farthest into the interior and against the rear surface of the center clutch driven hub.)