Hi,

iv got myself a crackin little bike that touch wood is running great. 
im after making the clutch a little lighter, I shot a nail through my left hand many moons ago and i think I could practice for longer if the lever had a lighter action. 
 

any tips or adjustments I can make? Iv seen online about sanding clutch plates and putting washers under springs. 
 

any advice would be greatly appreciated.

 

many thanks

The txt came in 1999 so it would help to know what year your bike is, if its the earlier <02 type clutch or the later txt pro >02 diaphragm clutch

Oh right, I’m with you, I believe it’s a 2006, it’s red and black and shiny. 😂

Are there any ways to adjust the weight of a diaphragm clutch?

5 hours ago, DustyCat said:

Oh right, I’m with you, I believe it’s a 2006, it’s red and black and shiny. 😂

Are there any ways to adjust the weight of a diaphragm clutch?

Set the clutch plate pack thickness to the minimum thickness as advised in the manual and also use a AJP Large master cylinder if possible . There are AJP Clutch Master cylinders available with Large and small reservoirs. Also available are Braktec Clutch Master cylinders that are  known incorrectly by the trials community as Braketech . Try googling them both and you will find out which is the correct one. Both are  dot COM addresses.

Use the long lever not a short or single digit mini blade and position the Master cylinder in board along the handle bar toward the handle bar clamps at the top  triple clamp. 

Position the lever so that you are pulling it with one finger at the end near the ball for maximum leverage . 

Adjust the lever to move away or be nearer the handle bar grip  using the 2 X adjusters one on the lever itself and one on the Master cylinder  main body as shown in the Owners Manual. That's one way to get the easy pull at the clutch without it getting complicated and more involved plus more expensive.

Ok great, that’s plenty to be getting on with.

i was trying to adjust the lever to get it set perfectly tonight and when it’s held right into the grip/bar the bike was still creeping in 1st gear and I think that’s why I’m struggling to find neutral. 
 

I will have look at the clutch plates to start. Any ideas where you find a workshop manual?
 

I have been pulling it close to the fulcrum point because my digit is not very long but I will try adjusting the controls around as well. 
 

thanks for the advice, really appreciated

32 minutes ago, DustyCat said:

Ok great, that’s plenty to be getting on with.

i was trying to adjust the lever to get it set perfectly tonight and when it’s held right into the grip/bar the bike was still creeping in 1st gear and I think that’s why I’m struggling to find neutral. 
 

I will have look at the clutch plates to start. Any ideas where you find a workshop manual?
 

I have been pulling it close to the fulcrum point because my digit is not very long but I will try adjusting the controls around as well. 
 

thanks for the advice, really appreciated

Hello Manuals available at ww.thehellteam.com/tech support/gasgas info.

Also  Video workshops at TRIALS PARTS USA  on Youtube

On 4/14/2026 at 3:56 PM, DustyCat said:

Oh right, I’m with you, I believe it’s a 2006, it’s red and black and shiny. 😂

Are there any ways to adjust the weight of a diaphragm clutch?

Are you 100% sure it's 06? The reason im saying that up to 05 they had a heavier belleville spring but in 06 they came with a lighter spring. A dragging clutch may hint at too thick of a clutch pack which also makes the clutch heavier. Personally i wouldn't waste my time playing about with master cylinders, they all use the same size piston and the differences are negligible

Thank you for the message, I was told it was 06’ but the V5 came through the door and it’s a 55 plate reg. So it could be a 05. 
 

so you think I strip it down and measure the thickness of the clutch pack and if necessary replacing the discs and the spring plate?

 

2 hours ago, faussy said:

Are you 100% sure it's 06? The reason im saying that up to 05 they had a heavier belleville spring but in 06 they came with a lighter spring. A dragging clutch may hint at too thick of a clutch pack which also makes the clutch heavier. Personally i wouldn't waste my time playing about with master cylinders, they all use the same size piston and the differences are negligible

Not to do with the size of the piston or reservoir with the bigger size clutch master cylinder , it is the position of the fulcrum being different between the two.

On 4/14/2026 at 8:51 AM, DustyCat said:

Hi,

iv got myself a crackin little bike that touch wood is running great. 
im after making the clutch a little lighter, I shot a nail through my left hand many moons ago and i think I could practice for longer if the lever had a lighter action. 
 

any tips or adjustments I can make? Iv seen online about sanding clutch plates and putting washers under springs. 
 

any advice would be greatly appreciated.

 

many thanks

If the clutch works nice right now, I would modify the lever to address your lever problem.  Shorty levers with perches moved way in on the bars and the lever adjusted so your finger can comfortably be at the clutch friction point.  You will rarely bend or bust levers in a crash and never crush your grip fingers behind the lever in a fall 🤓 inexpensive modification to try.  

 

The effective length of my lever setup provides very near double the leverage of a "close to the fulcrum point" setup.  105mm vs 55mm.  ... just measured it 

Setup works best for old veteran smashed up arthritic hands.  If you experience arm pump you likely need to adjust the start of the clutch lever friction zone even closer to the bars, shown in the picture is ideal such that your finger can curl one knuckle from the bars, like a comfortable trigger. 

On 4/15/2026 at 11:59 PM, Tr1AL said:

Not to do with the size of the piston or reservoir with the bigger size clutch master cylinder , it is the position of the fulcrum being different between the two.

Ive had both, rebought the older design when they went with formula in 2012 ish, never noticed much difference. Its lies in the toolbox as a spare

On 4/15/2026 at 9:37 PM, DustyCat said:

Thank you for the message, I was told it was 06’ but the V5 came through the door and it’s a 55 plate reg. So it could be a 05. 
 

so you think I strip it down and measure the thickness of the clutch pack and if necessary replacing the discs and the spring plate?

 

I can't really advise having never owned nor ridden a pre 06 gg, but at the time I remember people saying it made a noticeable difference when the light spring came in 06. There's also the chance someone has fitted the later spring to your 05. As for modifying or replacing the plates I wouldn't be in a rush to do that if the clutch is functioning ok

Edited April 20Apr 20 by faussy