ericm

I removed the factory knobs and plastic L-bracket things and replaced with allen head bolts and washers. The screen is solid now. I have a madstad screen and it's got its own adjustment so I don't need to use the Yamaha adjustment. I had tried reversing the L-brackets. Don't do that. It doesn't hold the screen any more solid and the knobs keep backing out.

Don't forget the new clutch nut.

I think the clutch cover is the same across all models. The XSR parts fiche gives an order to the clutch plates. I think I'd like to see the appropriate pages of the XSR shop manual to do this mod.

Japanese site showing installing the XSR clutch on an FZ. I got this from ADVrider. http://www.geocities.jp/motohiko01/MT-09/xsr900-clutch/xsr900-clutch.htm

Wow, that's perfect! Thanks!

The return spring on the throttle is stiffer than I'd like. It doesn't need to be that stiff, it's only operating a TPS. And it's got a return cable to pull it shut should it stick. Has anyone looked into reducing the tension from the return spring?

Looks like about $360 in parts before tax & shipping from RonAyers. When I get a chance I'll post what I think is the parts list for the conversion.

I did not compare all the parts but it looks like the clutch basket/primary gear is the same, and it's the inner hub and spring carrier that are the major parts that are different. Many of the clutch plates on the XSR are the same as the FJ, just fewer of them. The actuator in the case looks the same. Of course the various small parts that are different may add up. I wonder if the XSR's clutch cable has the bad bend in it, and if not, if it'll fit the FJ. If this cost like $300 I'd do it.

I'm going to do the same (powerlet on the left, move the stock SAE to the right) but wired for higher amperage to support an electric vest. I've already wired up a powerlet that I mounted to a small bracket I bolted between the passenger peg mount and frame.

There are bar end weights or spacers with the stock setup. They're made from aluminium so they are not very weighty. Yamaha part # 2PP-2624B-00-00 End, Grip 2 ( #24 on http://www.yamahapartspro.com/oemparts/a/yam/546a26d8f87002164cb28061/steering-handle-cable) I found the vibration to be the same or slightly reduced with the KTM guards and no spacers or weights.

I really like the trunk from my BMW GS, so when I sold it I kept the trunk. Tonight I finished an adaptor to mount the BMW trunk mount on the Yamaha luggage rack.

I fitted mine directly to the bars, removing the Yamaha bar end weights. The Yamaha bar end bolts are too long without the weight but the KTM bar expander bolts thread into the Yamaha bars. Done this way there is not a lot of clearance between the clutch cable and the clamp bolts (see pic above where the cable is touching the nut). There may be some combinations of clutch lever angle and position and guard position that can't be done as the guard clamp interferes with the cable. But it looks like many positions will work.

If you fit the mounting bolts from the front and put the nuts on the rear, there is more room for the clutch cable to pass by without rubbing against anything.

Wilbers information (from Klaus at Wilbers USA). Model 640: adjustable rebound and preload (threaded adjuster) $619 from Wibers USA Model 641: adjustable rebound, high and low speed compression, preload (threaded adjuster). $849 from Wilbers USA Remote hydraulic preload is not available. Hyperpro information (also from Klaus, he's a dealer): Model 466: adjustable rebound, preload (threaded) $709 Model 461: rebound, high and low compression, preload (threaded) $959 Both can take a remote hydraulic adjuster for $269 461 can be had with a length adjuster either +- 5mm or 0-10mm. Comes with coupon for 1st service free. Made to order per weight/riding style. Springs are purple or titanium black. They also have a Streetbox package for $699 with a model 466 set up for 180lb rider, progressive fork springs and oil. Pic of 461 on an FZ-09:

A larger MC piston will result in firmer brake feel, less travel, and less braking force for a given amount of pressure at the lever. A smaller MC piston will have more travel and more braking force for a given amount of pressure at the lever.