Hydraulic clutch conversion.

OK. Couldnt find the edit button for the last post!
I tried the link and couldnt find the part that I linked to so as my build thread is busy enough , I thought I should just do the conversion here (the title is already there,which should help people using the search engine) and link to it from my build thread.

So,here we go. My attempt at fitting an hydraulic clutch actuator(?) from a ZX9R to my KZ1000CSR.
Forgive me if Im repeating myself.
Part the 1th
Original cover laid out on some 9mm MDF.

Piece of cardboard to locate the holes

Transfer holes to MDF

Cut out MDF

Locate and drill hole for slave cylinder

Part the 2rd

Mount the slave and test the fit


I made a lot of adjustments to the MDF to get the profile looking and fitting as best I could

I ended up with something like this

Next, I transferred the holes to a piece of 10mm aluminium plate


......and then I got distracted by other things.

Until today,when I turned my brain on again and had a look at things.

Part the 3nd

The idea of the MDF is to make a template that I can use with a router. So,the MDF has to be as good as I can get it as any problems will come out directly onto the aluminium plate. So,getting the template fitting well is pretty important.
(its a lot easier to work on the MDF than on a plate of 10mm aluminium!)

So it took a few goes with the MDF to get it right.Also I changed over to 18mm for ( i hope) the final template


Sanding the edges to get rid of any bumps or weird things that the router will pick up


Masking tape over the alu to mark an outline


everything lined up and the outline marked


The aluminium was a lot easier to cut than I thought.This is what I used.


Keep it well cooled with WD40 or something


I made sure to cut outside the line but as close as possible to the line.This will mean the router will do the final cut though without having to struggle too much.


and thats it for tonight folks.Tune in tomorrow when I will mainly be attacking the aluminium with a router without losing an eye! (Ihope)

Nice write-up Davido. You have motivated me to get back to my conversion.

Why a hydraulic clutch? I have had them and prefer cables for bikes, especially if I am going to be drag racing it.

Easier to pull, especially if you want to run heavy duty springs. I also ride my bike in a city so holding the clutch for extended periods of time is easier also. You don't have to lube it. Even with a properly maintained cable you still have to mess adjustments due to cable stretch and wonder if the head is going to pop of in the middle of a long trip. That's why I'm doing it. Davido's reasons may differ.

OutsiderKZ900A4 wrote: Why a hydraulic clutch? I have had them and prefer cables for bikes, especially if I am going to be drag racing it.

I fitted the complete front end of a ZX9R to my bike,with the brake resevoir.So I wanted to fit the clutch resevoir for symmetry.( I like symmetry) Also,my original cable and lever control were shagged out and I didnt want to buy new ones .
I dont plan on drag racing and as kaw-a-holic says,its lower maintenence but mostly,I wanted to have a go. I saw some pictures of other bikes and thought it looked like a nice idea and not too difficult,so,why not.My whole build so far has been about learning new things,fiberglassing,welding ,powdercoating and working with aluminium.
Saying that,I am just having a go and if it dosnt work out,I can always switch back to the cable option.Nothing ventured,nothing gained.

Part the 4st,

This morning I lined up and bolted the oversized alu plate onto the 18mm MDF template.


This is what Im going to use in the router(its an old one)


I camped it all down to the bench and had at it.


rotating the whole thing while keeping everything lined up properly


and this is how it came out.


Im happy with the tap and die set that I bought the other week.


So,this is how it sits at the minute.


So far,so good.The aluminium is remarkably easiy to work with.Normal woodworking tools with lots of cooling WD40. Im thinking it looks a bit boring as is,so Im going to play around with the template and mark out some relief lines. See what more I can get away with using the router.
More later.

davido wrote:

OutsiderKZ900A4 wrote: Why a hydraulic clutch? I have had them and prefer cables for bikes, especially if I am going to be drag racing it.

I fitted the complete front end of a ZX9R to my bike,with the brake resevoir.So I wanted to fit the clutch resevoir for symmetry.( I like symmetry) Also,my original cable and lever control were shagged out and I didnt want to buy new ones .
I dont plan on drag racing and as kaw-a-holic says,its lower maintenence but mostly,I wanted to have a go. I saw some pictures of other bikes and thought it looked like a nice idea and not too difficult,so,why not.My whole build so far has been about learning new things,fiberglassing,welding ,powdercoating and working with aluminium.
Saying that,I am just having a go and if it dosnt work out,I can always switch back to the cable option.Nothing ventured,nothing gained.

Gotcha. I was just curious.

Thanks for this post Davido!

I'm curious to see how it works out so waiting to see your feedback.
May need to do something similar on the wife's 440 ltd

I've thought about doing something like that but using the stock cover. I use to have three but lost them to Meth Head scrappers. Maybe one day I'll try it.
Steve