cosmikdebriis

To return to this rather old topic... In the end I used friction plates from some sort of generic Jap 125 and they worked a treat (though I did gave to file down the tangs a bit to fit the basket). Problem is, I now also own a 350 Sherpa trials outfit with a slipping clutch and am considering the same mod but... Can't remember which Jap 125 plates I used. Anyone got any idea?

Also, regards air tools (or battery operated rattle guns for that matter). Great for undoing, but I don't really trust them for doing things back up. Too easy to strip threads. Nothing quite like the feel you get if you do it by hand.

Just thought I'd add a picture of the tool I made up to help in the disassembly of the forks. There is an allen key in the bottom that holds the damper rod in place and this is not always straightforward to undo/do up as the damper rod can spin along with the allen bolt. Luckily there is a slot machined in to the top of the damper rod (marked "C" in the picture) and I used this, along with the tool, to stop it from spinning whilst undoing the allen key. You may be able to use a long screwdriver for the same but if you don't have one... read on. I used a bit of steel rod about 18" long that I had lying about (tube would do at a pinch so long as it fits inside the fork stanchion). I then cut/hacksawed a slot in it and made up a bit of flat bar (about 1.5mm thick) to (snugly) fit in the slot. I then ground it to the approx dimensions in the pic. It's the chamfer between the two diameters that locates in the slots in the damper rod. The protrusion of the smaller diameter is just there to help locate it. (and so is much better than a screwdriver). Anyway, it fitted in a treat and did the job perfectly. As it happens I used a bit of stainless for the insert because it was the first thing I laid my hands on. You will need something fairly hard or it may bend. Took about 10 mins to make and I now have a handy arrow if anyone tries to nick my bike wink emoticon

Hi... I'm considering replacing the original clutch plates on my Alpina with more modern "friction material" as available from a certain well known Bultaco supplier (that I may not be supposed to mention by name but I'm sure it's pretty obvious). So... Is it worth the ninety odd quid it's going to cost me? I should say, I'm in the middle of restoring the bike (1972 175 Alpina) and have not really tried the original clutch to see if there are any faults, just thought it easier to do now if it's worth it? Thanks in advance... Dave