kik

I purchased the parts from www.cyclepartswarehouse.com

Just got done with the clutch upgrade. The hardest part was to get the clutch boss nut off. This is a 30mm nut that's held in place by two indentations and (what looked like) red Loctite. Since I didn't have a clutch holder tool I ended up using my air impact wrench. I put the bike on the side stand, shifted in 6th gear and used the impact wrench to undo the clutch boss nut. After that it was a piece of cake. All-in-all the job took about 4 hours, but that's because I am not a professional. I needed a 30mm socket (clutch boss nut), a 5mm hex bit socket (clutch cover bolts), a 10mm socket (pressure plate bolts), a torque wrench, and a diagram of the XSR900 and FJ-09 clutch. I used most of the friction and clutch plates from the FJ-09's clutch. There are a couple of additional friction and clutch plates, which you will see on the parts diagram, which come into play in the XSR clutch and are not part of the FJ-09 clutch. I strongly recommend having the XSR900 service manual as well. It shows how to put the plates in and the torque values for all the bolts and nuts you touch. I found a copy of it here XSR 900 Service Manual I modified my original parts list so this is the new and tested parts list (see below). The total parts cost is around $250. Not bad at all. The thing I noticed right-away after the upgrade was how light the clutch pull is. Shifting between gears is a two fingers job now. Downshifting is so much smoother as well. I really appreciate the light clutch pull in traffic and recommend the upgrade to all FJ-09 owners.

What you mean by 'other' site? I am really interested in a XSR service manual. Could you PM me or something with information on where to get it. Thank you!

I've compiled the parts list and pricing. I haven't done the upgrade yet. I was hoping to do a how-to video and upload it to YouTube, but I've never done a YouTube video before and I am afraid I'll mess it up. However, I ran the below list by a contact at Motorcyclist magazine who confirmed that these are all the parts that will be needed to convert the clutch. I hope this list helps you get an idea of how much it would cost, parts-wise. I'll definitely update this thread if I get to doing the job myself. It should be a fun project, I just have too much on my plate this summer.

I emailed Motorcyclist Magazine about installing an XSR900 clutch into the FJ-09. Last email I got from them is that they are going to try it on their FZ-09 and let me know how it goes. Possibly as soon as next week. The FJ-09 and FZ-09 clutches are the same, so if it works on the FZ, it will work on the FJ. I have been working on the parts list myself and I've compiled the list of parts needed. My calculation is around $300 for parts. I will report back with part numbers and details as soon as I hear back from Motorcyclist Magazine. Stay tuned.