Magura clutch for the 2012 WR450F

[Corkster]

I sent an email including photos to Magura asking what parts I could use to make up a clutch kit for the 2012 WR450F. This was the response:

_________________________________________________________________________

Hi Mike,

Thanks for the good pictures - I can now see where the problem lies.

Sorry for the delayed response - I was out of office all week and just returned this morning.

Looking at your pictures I would not recommend trying to fit a hymec to your bike.

The slave cylinder should always operate in a straight line. If it pulls off line it will wear quickly and cause you problems in the future. Every slave has a conical fitting at the connecting bracket but it is only for 3 to 5 degrees of sidewards movement.

The whole idea is that when a Hymec is fitted properly once that it provides a long term trouble free improvement.

In order to do that correctly for your motorcycle you are looking at modifying the slave retaining bracket and the activation arm on the motor.

It is never good for the company turnover to recommend not buying our product but it is important to us that it works correctly after fitting and that will be difficult with the limited space avilable to you.

Regards - Conor

Mit freundlichen Grüßen

Best regards

Controls MAGURA

-----------------------------------------------------------------------------------------

Phone : +49 7125 153 0

Fax : +49 7125 153 267

Mail to : controls@magura.de

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MAGURA

Gustav Magenwirth GmbH & Co. KG

Stuttgarter Str. 48 - D-72574 Bad Urach

www.magura.com

www.fastest-brake-on-the-market.com

www.facebook.com/magurapassionpeople

HRA 361077 - Registergericht Stuttgart

Persönlich haftende.Gesellschafterin: Munz-Magenwirth Verwaltungs GmbH

mit Sitz Bad Urach - HRB 360237 - Registergericht Stuttgart

Geschäftsführer: Siegfried Knüpfer (Vors.), Ralph Berndt, Edmund Hirth

[GP1K]

Well that's interesting... I called Magura prior to ordering my Hymec clutch as I couldn't find a part number for a WR450 past 2008. They gave me some part numbers and said it should work (I purchased it throught the TT store). The install looked like more than I wanted to take on, so I had a mechanic install it. He had a heck of a time getting it on, and said the bracket was a joke and clearly noone had actually tried fitting one to 2012, but he got it to work... soft of. The pull at the lever was no better than stock, which was the main reason I bought it in the first place. And it didn't engage smoothly, you could feel it bind and kind of catch on the way out. My first ride on it I nearly got stranded as the clutch stopped engaging. As in, I could let the clutch lever clear out and the bike would just rev like it was in neutral. I managed to limp it back to my truck and called Magura the following Monday.

They wanted to see the unit to make sure there wasn't anything wrong with it, so I had my mechanic swap my stock cable back on. He showed me where it was binding and how the bracket doesn't really line up correctly. Once Magura got the clutch back they verified the unit itself was ok, and wanted to talk to my mechanic about the install, so he called them and talked to the guy and the end result of that was Magura recommended not installing this little bushing that goes in the bracket where the cable goes through to the slave cylinder, saying it's 'self-centering' and not necessary, and was likely causing the binding I was feeling.

The other change was the master cylinder. Orginally they sent a 10.5 master, but the second time they sent a 9.5 master instead. The 9.5 would give a ligher pull, as long as it had enough throw to fully disenage the clutch. Based on how much free play I had, Magura felt this would work. So back to my mechanic again for another swap.

This time the pull at the lever was significantly less than stock, I'd guess 50% or so. It went from taking a strong 2-finger pull to a very light 2-finger, almost 1-finger pull. And the binding feel was gone. Initially there was still a lot of free play, which Magura said if there's too much it can cause clutch drag. So another quick trip to the mechanic to shim the bracket and then the free play was right in spec.

I've had a few rides on the bike now, and so far so good. The pull remains light and smooth, and I haven't had any issues with it. It's nearly impossible to find neutral with the bike running, but easy with it off. I'm not sure if the clutch has anything to do with that, or if it's just the nature of the beast? It was a frustrating process, with several trips to my mechanic and having to return my original unit. But in the end, Magura made it right, they gave me another brand new unit to replace my (now used) original at no charge. And it now works exactly as I'd hoped it would, and I'm not going to need Popeye forearms to ride my bike.

The one thing I can't know is how it will work in the long run. I don't know if the slave is over 3-5 degrees off and is going to wear itself out prematurely. It looks straight to me if I pull the clutch and watch the arm/cable, looks like it's going straight in & out, but 3-5 degrees isn't much, I could be missing it? Kinda makes me want to call the guy at Magura I was working with and see what he says about Conor not recommending it.

[Corkster]

Interesting how we can get different answers. I suspect the install will be fine once you get it right and the reason they officially don't recommend it is because of all the messing around with the bracket in order to make it fit. To be a realistic bolt-on substitute they would have to supply a custom bracket with the kit. Do you have the part numbers that you used and a photo?

[Ricky Roma]

Corkster, have you been on Dirt Bike World for information on this? There's a thread with a few guys that have these on their 2012 WR's that don't seem to have had any issues.

Edited June 21, 2013 by Ricky Roma

[JDLowrance]

Photos would be great.

[Corkster]

This is the DBW thread

http://www.dirtbikeworld.net/forum/showthread.php?t=95287&page=2

The photo shows a custom aluminium bracket. I phoned Ballards and they said they were waiting for supplies to come in. Will be at least 2 weeks and they want $390!!

[GP1K]

Interesting how we can get different answers. I suspect the install will be fine once you get it right and the reason they officially don't recommend it is because of all the messing around with the bracket in order to make it fit. To be a realistic bolt-on substitute they would have to supply a custom bracket with the kit. Do you have the part numbers that you used and a photo?

Unfortunately I don't, as what they sent me the second time wasn't exactly what I ordered, and the second one didn't come in it's original box, it was just bagged and put in a shipping box.

However, after reading this thread yesterday I called the guy I had been working with at Magura and told him about what Conor said. He was going to try and talk to Conor about it. I looked at my bike again, and the cable *looks* straight, the slave cylinder is not touching the starter or anything else and barely moves when pulling in the clutch. Free play is still a shade over 1/8", as it should be. So I guess I keep riding and keep my fingers crossed.

[GP1K]

Interesting how we can get different answers. I suspect the install will be fine once you get it right and the reason they officially don't recommend it is because of all the messing around with the bracket in order to make it fit. To be a realistic bolt-on substitute they would have to supply a custom bracket with the kit. Do you have the part numbers that you used and a photo?

Peter from Magura called me back yesterday. He said the kit you had is not what I have, the brackets are different and that was the problem. I did get the part number from him as well, 0120523-40 and that's with the 9.5 master like I have. HTH

[Corkster]

Peter from Magura called me back yesterday. He said the kit you had is not what I have, the brackets are different and that was the problem. I did get the part number from him as well, 0120523-40 and that's with the 9.5 master like I have. HTH

Sorry, now I am confused. I don't have a kit. Does your kit 0120523-40 include the correct mounting bracket? Very cool if it does; and a shame that Magura head-office doesn't know about it!

[GP1K]

Sorry, now I am confused. I don't have a kit. Does your kit 0120523-40 include the correct mounting bracket? Very cool if it does; and a shame that Magura head-office doesn't know about it!

Well that depends on how you define 'correct'. It works, but I know for a fact Magura has never had a 2012/13 WR in their hands to actually test fit it to. Also after talking to my mechanic about the install, he was advised to not install this one little bushing that goes in the bracket where the cable from clutch arm to the slave cylinder goes though, as that's where it was binding before. I've had several rides on it now with no problems. The pull is light, and the engagement feels great. The concern though is if there's too much of an angle from the clutch arm to the slave cylinder it could cause wear there, though Peter had me check that and see if the slave cylinder is moving when pulling the clutch in. It moves, but just barely, maybe a millimeter at most, so he thinks it should be fine.

[JDLowrance]

This whole thread is confusing.....

I think the disconnect is comming from the fact that one of you is talking to someone from Magura in the States and the other is talking to someone from either Magura or Ballard's (possibly making a custom bracket) in Australia.

Sure would be nice to get to the bottom of it as I would be interested in purchasing one for my 2012 once sorted.

[GP1K]

This whole thread is confusing.....

I think the disconnect is comming from the fact that one of you is talking to someone from Magura in the States and the other is talking to someone from either Magura or Ballard's (possibly making a custom bracket) in Australia.

Sure would be nice to get to the bottom of it as I would be interested in purchasing one for my 2012 once sorted.

The person I've been talking to is at Magura USA in Illinois. I did not get any kind of custom bracket, it's just the one that comes in the kit. But it's a kit for an older WR, and has not been officially test fitted or whatever to a 2012 as they have not had access to one yet.

FWIW, I consider mine sorted now. It works great, and the pull is nice and light. But yes it was a PITA getting there. Hopefully it would be smoother for you or anyone else wanting one going forward.

[Ride-n-Hard]

If anyone cares, I just received this reply from Magura. However, searching out that part number I'm not finding any ads at mc shops yet to back that up.. Which kind of concerns me if there is a custom bracket to mount it. Also what is intersting is the part number i was sent is different then the part number that GP1k got. So some more research.

Thank you for inquiry.

We have Jack Hymec Clutch kit Magura #0120524-40

for WR450 12-13 no hot start.

Please let me know if you need more information.

Regards,

Peter Ubellacker

Magura USA

Ph. 618-395-2200 ext 223

Edited September 4, 2013 by Ride-n-Hard

[MidlifeCrisisGuy]

Thank you for sharing all this information.

 

I too want to put a hydraulic clutch on my 2012 WR450.

[JDLowrance]

Sounds like Magura have finally got a kit for the 2012-14 WR450F. This is good news. Now we just need someone to order the kit and try it out.

 

I've dealt with Peter from Magura in the past (Sumo brake set up) and he is a good guy to deal with....very knowledgable. He will sell to the public as well so no distributor needed.

 

If someone beats me to the punch, let us know what the cost is, ease of installation and lastly how it works!

Edited September 4, 2013 by JDLowrance

[MidlifeCrisisGuy]

I called Peter and ordered it.  

 

We discussed installation and there are a few things that need to be right or it won't work properly.   I'll write it up when I install it.

 

This kit is stock with a 10.5 mm master cylinder.   That won't do much to lighten the pull.   Peter is going to put a 9.5mm master in mine per my special request.   He is a bit worried about free play and drag issues.  Again I'll share how it works out.

 

RnH: thanks for doing the foot work on it.   Much appreciated.

 

FYI, I didn't find the clutch on my WR450 to be terrible, but I'm really looking forward to having a hydraulic clutch like those orange bikes.

 

I wonder how much of the WR450F clutch pull is related to the WR clutch arm which is different than the YZ clutch arm.     The YZ clutch cable goes on the left side of the engine.   The arm is different because the WR starter is in the way on the WR engine.

Edited September 4, 2013 by MidlifeCrisisGuy

[Ride-n-Hard]

A new update all. This is what was just emailed to me.

Thanks for update what is on the web.I did slip on the number it should read 0120523-40.The -30 is with hot start, -40 is with no hot start.Bracket issue: Yes, the kit includes a bracket.It also includes a long split nipple to hook ourslave cylinder piston rod on at top of clutch arm.We include spacer, if needed, for proper free play.10.5 vs. 9.5 master cylinder: We use 10.5 in thiskit. But found the 9.5 will pull clutch armenough with proper free play set up, otherwise it may notfully clutch and makes bike pull when in gear. The 9.5 master makes lever easier to pull. The 0120523-40 comes with10.5 mm master cylinder, reason less hassles from users aboutclutch drag. If you want 9.5 I can offer an extra master for about $65.00would have to be shipped from Olney, IL.Please let me know if you have more questions.Regards,Peter UbellackerMagura USA

[GP1K]

I called Peter and ordered it.  

 

We discussed installation and there are a few things that need to be right or it won't work properly.   I'll write it up when I install it.

 

This kit is stock with a 10.5 mm master cylinder.   That won't do much to lighten the pull.   Peter is going to put a 9.5mm master in mine per my special request.   He is a bit worried about free play and drag issues.  Again I'll share how it works out.

 

RnH: thanks for doing the foot work on it.   Much appreciated.

 

FYI, I didn't find the clutch on my WR450 to be terrible, but I'm really looking forward to having a hydraulic clutch like those orange bikes.

 

I wonder how much of the WR450F clutch pull is related to the WR clutch arm which is different than the YZ clutch arm.     The YZ clutch cable goes on the left side of the engine.   The arm is different because the WR starter is in the way on the WR engine.

 

My kit originally had the 10.5 master, and the pull was no better than stock. But it was also binding at the slave cylinder as well. So I sent the master back to Peter to make sure there was nothing wrong with it, and had my mechanic give him a call to discuss the install. There was nothing wrong with my original master, but since my free play was ok and the lighter pulls was the main reason for purchasing a Magura, he sent a 9.5 master back, and said to NOT install this one little bushing that goes on the bracket where the cable comes out of the slave cylinder (if that makes sense?) as that's what was binding.

 

With the 9.5 master on and no bushing, the clutch now works great, and is WAY lighter than stock. Not quite KTM light, but close enough. I've got a few more hours on the bike since my last post on this, and it's still working great. My only complaint at this point (which I discussed with Peter and he said they'd look into it) is the thingy that holds the cable from the slave into the arm from the clutch itself. It's made of plain old steel or something, and starts to corrode at the mere sight of water. It really needs to be stainless steel or something. I just squirt some WD40 on it now and then and it seems to be ok.

 

So again, quite a PITA getting there, but now I'm quite happy with it and it was totally worth it.

[Ride-n-Hard]

Thanks for the update. Seems odd and I guess I don't really understand Peters email about why they are selling with the 10.5 and not the 9.5. For me I don't really want to buy both parts since like you said the goal was a lighter pull.

Edited September 4, 2013 by Ride-n-Hard

[MidlifeCrisisGuy]

Thanks for the update. Seems odd and I guess I don't really understand Peters email about why they are selling with the 10.5 and not the 9.5. For me I don't really want to buy both parts since like you said the goal was a lighter pull.

 

I think they are getting the message.   Peter is substituting a 9.5 for the 10.5 for me.   I am not buying a second master cylinder.