G'day Jayjayridge,
I converted my Rap to a hydraulic clutch a bit over 12 months ago & I'm glad that I did. After doing some research from the Raptorchapter, the TL/DL forums, & picking a couple of Suzuki mechanics brains, this is how I went about it.
I used Suzuki DL1000 V-Strom parts over SV1000 or TLR1000 (TLR is different anyway) because the DL has coffin type master cylinders & I wanted my Rap to have a low profile across the bars. I also used a couple of Suzuki parts where I could have modified the Raptor parts, but I didn't want to ruin any of the originals.
The parts list is as follows:
DL1000 V-Strom clutch master cylinder (brake master cylinder as well so they match). These were the only used parts I purchased, and the only parts that weren't cheaper than new ones!!
DL1000 V-Strom clutch slave cylinder (comes complete incl. rubber seal & bleeder etc) - PRODUCT NUMBER: 2316006G02
DL1000 V-Strom left hand push-rod - PRODUCT NUMBER: 2311126D00. I had to cut this item shorter (114mm), you would think that it would fit being a factory part.....but it doesn't!! To check the length to be sure, bolt the DL1000 V-Strom sprocket cover on & use a vernier caliper to measure the depth from the outer most part of the sprocket cover to the clutch seal inside the crank case. Then measure the depth of the hole in the slave cylinder to the outside of the rubber boot. Add these together & this give you the maximum length you can use which gives a small amount of free play before the clutch engages.
DL1000 V-Strom Spacer - PRODUCT NUMBER: 2317106G00. For mounting slave cylinder.
Bolts - 1 off M6 x 70 & 1 off M6 x 65 for mounting slave cylinder. Suzuki sell these but I couldn't find the part No. Cheaper at the hardware store anyway.
DL1000 V-Strom Sprocket Cover - PRODUCT NUMBER: 1136006G00. This item differs from the Rap cover in its shape at the swing arm end, other than that it bolts straight on. I made a template from the Raps cover & cut the Suzuki cover to match. I then plastic welded a new strip up the end where I modified it, then covered it in fake carbon fibre shrink wrap. Looks like a factory item!!
The bolting for the sprocket cover (other than the slave cylinder mounts) use the Rap bolts (M6 x 35). You will notice that the Suzuki Sprocket Cover uses a slightly different bolting arrangement, but all the holes are there in the crankcase. There will be one one hole in the Suzuki cover at the bottom you can't use unless you tap the matching hole in the crankcase, which I haven't done yet either.
Hydraulic clutch line - 1050mm long with a 90ยบ banjo at the master cylinder end & a straight banjo at the slave cylinder end.
On the electrical side of things, you will have to modify the Rap wiring connection to suit the Suzuki connections on the clutch master cylinder, or just by pass it. It was too hard to find a connecting plug that matched the Rap's plug to make a patch loom. So I spliced into the Rap's loom & made my own patch loom leaving the original plug on the loom so I could convert it back to a cable clutch if for some stupid reason I needed to.
One thing you might want to consider when going to all the trouble of doing this conversion is machining a brass or nylon sleeve that covers the pushrod. According to the DL forum, the clutch mechanism is prone to seizing as the pushrod is exposed to all the chain lube as it runs close to the sprocket. However, regular maintenance will stop this problem also.
I tried to attach some pics of my bike for reference, but the files were too big. I hope my dribble will be of some use to you and others anyway
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Stay upright & cheers from
Boofhead