Honda VFR400 NC24 Modifications Section

NC21 Hydraulic Clutch

NC30 Forks

NC21 Hydraulic Clutch System

The VFR400R/Z (NC21) uses a Hydraulic clutch system instead of the cable-type system found on the NC24/30/35

This system is a direct fit to the NC24 and requires no modification!! ^_^ The system can be made to fit the NC30 / NC35 with modification but that is not covered on this website

I am unsure why Honda did not use this system on the later NC models, maybe it was cost issue as it is more expensive than a cable clutch system??

Why use the Hydraulic Clutch system?

To fit the clutch, the following parts are needed!

Fitting Guide

Fitting of the NC21 clutch system is quite a simple procedure and should take approximatly 1 hour of time to complete. The lower fairings are needed to be removed before any work can start. The nose-cone can be left on the bike.

Remove the old system


  1. Remove the Clutch Lever from the handlebars, Remove the 2x8mm retaining bolts.
  2. Unbolt the gear linkage from the gear selector shaft. Remove the 1x10mm retaining bolt and pull the linkage off the splined shaft. Not necessary to undo the other end, so let the linkgage hang down out of the way
  3. Unbolt the Sprocket cover. 4x8mm bolts need to be removed from the cover. Take notes of their locations, they are all different lengths.
  4. Unscrew the clutch cable from the sprocket cover and pull it out of the bike
  5. Remove the pushrod from the engine.

The old system is now removed from the bike!! Fitting of the Hydraulic system can now begin. Before installing the system, check that it is all functioning properly and clean.



Fitting the new system

Sprocket Cover / Slave Cylinder

The following picture will help with the instructions below, it shows the sizes of the bolts for the sprocket cover

  1. Install the clutch slave cylinder into the sprocket cover using the two small bolts (6x20 [bottom right] / 6x28 [bottom left])
  2. Install the NC21 pushrod into the engine.
  3. Install the assembled NC21 sprocket cover in the place of the NC24 sprocket cover. Some of the original bolts can be used but the top left hand bolt is too short so the 6x100 bolt needs to be used here

Master Cyliner / Reservoir

This bolts where the old clutch lever was, line the fixing bracket up with the indentation mark on the handle bar

Hyrdaulic Pipe

This can be awkward but install the pipe between the Master and Slave cylinder, making sure to use a washer on each side of the banjo bolt. Route the cable through the bike. This picture might help to show where the pipe should go. I secured the pipe with plastic cable ties.

Bleed air from the system

This procedure is the same as for bleeding air from the brake system, remove the top from the resevoir and add fresh DOT4 fluid, using a bleeding kit drawn the air out of the system from the bleed nipple, which is located on the slave cylinder.
This took quite some time, to speed it up I opened the bleed nipple and while depressing the clutch lever, sucked on the nipple to help pull the fluid through. Then I bleed it until no more air is visible in fluid. Then refit the cover to the resevoir making sure it is tight and sealed properly

Test!

Make sure the cable does not catch or obstruct anything on the bike, and the handle bars still move freely from side to side. Start the bike up try the clutch, if it is working ok, take it for a drive and admire ^_^


Pictures of my bike with clutch!





you can see in the last picture I still needed the 6x100 bolt becuase i only had the original bolts when this was taken, the original NC24 bolt (6x70) was too small >.<

Conclusion

The hydraulic clutch system is very smooth and works efficiently, this was a good modification to do and cost me little money £ 16.50 / ¥ 2430 for all of the parts (second hand)

1994 NC30 Front End

NC30 forks

1994 Forks / Yokes / Handlebars / Brake Calipers / Wheel / Discs / Mudguard

-Coming Soon-

Last Updated: 28th October 2008 @ 18:55:18

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