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Old July 10th, 2019, 08:22 AM   #41
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I've finally gotten around to doing my "New Gen" to "Pre Gen" clutch assembly swap.

Originally purchased the entire used "New Gen" clutch assembly off Ebay for a reasonable price:

Everything about the used (2009) clutch assembly was great except for the "drive" plates, two of them showed some blue-ing. So I ordered replacement drive plates for this project.

People always like to know how much the parts weigh, so here's a pic of the complete "Pre Gen" clutch assembly:

Here's a pic of the complete "New Gen" clutch assembly:

The difference in weight between the two is:
"Pre Gen" clutch assembly = 3069 grams (6.766 pounds)
"New Gen" clutch assembly = 2891 grams (6.374 pounds)

So the "New Gen" clutch assembly is 0.392 pounds lighter. This is nice to know, a lighter clutch assembly will help the engine rev more freely.

Here's a picture of the difference in the clutch actuator rod:

As you can see the "New Gen" rod has a shorter top section than the "Pre Gen" rod.

I should have my 2005 EX250 finished and ready to ride by this afternoon.
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Old July 11th, 2019, 12:13 AM   #42
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Name: Chris
Location: Bristol, UK
Join Date: Feb 2016

Motorcycle(s): ZZR250, VFR800

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I didn’t have a new gen rod, so never compared them. I just used a 2mm washer on the old rod to take the slack out so that it would lift the inner basket, which has worked fine.

You will now find that the pre-gen knock of death has gone !
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