TOPIC:

The plan is to replace the front sprocket cover with an aluminium plate to carry the hydraulic clutch. Anybody advise on the thickness of the alu plate I need to buy? As a stab in the dark,I was thinking 8mm.

They make a kit for changing to a hydraulic clutch. You can buy it from Z1E but it is expensive. I'm hoping you come up with a cheaper alternative.

I gotta see this.
Steve

Its nothing special. Many of the builds here have this type of conversion.I got inspired,had a thunk and it looks straight forward enough.
I already have the caliper/piston (not sure what its called) from a ZX9R. All I need now is some alu plate and some spacers.How thick the plate though,Im not sure.Hence the post.
Im after something like this;



This is from
www.badseeds.fr/construcbstwo.html
A fantastic build .FromFrance, I think.

Davido, that's pretty awesome. What year ZX9 is the slave cylinder from?

Slave cylinder. Thats the word,thank you. The one I have is from an early model,I think 1995 or 1996.



So, anyone know what thickness alu plate I should use?

I figured that Black Banshee would have chimed by now. If I were to take a guess I would say 8mm is good. I don't know much pressure is required. I'm assuming no more than hydraulic brakes, if that's right 8mm should be good.

MINIMUM thickness is 10mm.
Anything less will flex when the clutch is applied.

Thankyou zed1015.

davido wrote: Slave cylinder. Thats the word,thank you. The one I have is from an early model,I think 1995 or 1996.

So, anyone know what thickness alu plate I should use?

Are using the same push rod for the clutch?

Yes,I reckon that I can cut and shape the alu plate, drill all the holes where they have to go (copying the original cover)and bolt on the slave
cylinder. Then it should be just a matter of getting the distance out from the engine right . So, if I measure from the inner most point of the old cable operated unit,where the ball bearing sits and copy that,I should be alright.The theory (in my head at least) is that,the ball bearing (and hence the rod) should remain at the same distance from the engine as with the original cable system.
Ill use hollow tube of whatever thickness the bolts need (M6?) and just trim it to the right length to act as spacers. Maybe aluminium tube or maybe stainless,not sure yet.
All this is just coming out of my head and maybe Im missing something. So,please,if anyone has any ideas,if this sounds daft,let me know.

I dropped in to the alu shop today but they dont have any 10mm plate,so Ill have to go out of town for it.

OK,Ive started the conversion.For anyone whos interested you can follow it here;
www.kzrider.com/forum/11-projects/594313...ild?start=120#675500
(I hope that works)
Anyway, Itll either be useful to others who want to do the same job or itll be a 'How not to do a hydraulic clutch conversion' Fingers crossed it all works out and nobody loses an eye!