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Thanks to zukedave for the idea. Last year when I bought the clutch basket and clutch assys, I also got the sprocket cover complete with the actuator assy from the same bike. KZ900. Dave told how he modded his so it wouldn't be so stiff and he had more control. I'm tired of my stiff clutch and going through cables every two years so I decided to copy his idea. This is what I came up with.










I was bending some PVC for Bossie's hut with my heat gun. PITA so I decided to let the sun do it for me.



Steve

Why does that help? Is it because it's longer so more leverage?

That's the idea. It was getting dark so I'll put it in in the morning and see how it works. Like all mods there will probably be some adjustments.
Steve

Interesting.

I'm going out to fit it now. We'll see how it works.
Steve

Looks good. I find the lever has more movement than necessary, so this should work well.

Well it may be time for Steve to change his handle on the forum to - Archimedes -

OK, I know it's only KZ-related because you mentioned your bike - Bossie - but what exactly are you doing with the PVC tubing?
I'm curious because I've had a few experiments with PVC structures myself...

Got it installed. The clutch feels like a much smaller bike. The wind is supposed to really rip about noon so I'm off to Depot and town before it does. It's already windy but I'd better move. I took some clips and will post them later.
The PVC is what I have laying around. I'm going to make a Quonset hut for the bike with some corrugated plastic sheets. I'll try to get a pic while I'm there.
Steve

Back. Amazing is the word for it. Easier to pull, I can shift faster and don't have the tendency to dump the clutch. I'm uploading some clips now.
Steve

Finally uploaded. I'm going to make a spacer to go under the adjusting screw. The Motion Pro cable is too long so I had to add the two washers. Was at the end of the three adjustments. As far as I can tell the mod didn't make it any worse, maybe took up a little slack.
1/4" should do it maybe a 3/16" ball bearing. If I get a REAL cable, I might to go without one..
Steve

This stuff is great. I used it on my daughter's green house 17 years ago and now it's Bossie's shed/tool crib. Last year I threw together a shade cover on the front so I would have a place to work on her out of the sun. It doesn't radiate heat like sheet metal or plywood and is fairly cheap $21 for a 2X12 sheet. Bossie's hut will be 10X12 and three sided next to the house. The shed is right next to the road where the local Meth Heads can get at it.







This is the item I use to shape aluminum. It's made for wood but it loves to eat aluminum. I got it at Depot.
Steve

Bossie's , gonna LUV YA !!
Pete