TOPIC:

Had another look at the Easy Clutch again today. If I install the gold housing in 180 degrees from how the instruction say. The actuating arm hits the aluminium housing. So cant be installed.  If I move the arm a third of a turn. Its too far forward.  My next move is to check and make sure the ball bearing is installed behind the clutch.                                                                                                                                                                                                                       
 

You are close.  The gold housing stays the same.  You have to keep moving the actuating arm around until you get it.  I looked at it so many different times and moved it around plenty as well.  It will work, just keep moving it. 

So what was it that you turned 180 degrees? Because the actuator sits on 3 balls in a triangle shape. There is only 3 positions it can sit. Each position is 120 degrees from the other.
This is where my actuator sits when I follow the instructions. But I run out of adjustment in the cable and the rod is still not being activated.                      
 

You have to adjust the acutator to rod play with this screw first, before you adjust the clutch cable play.

 

I've screwd that right in. But dont feel that it is making contact with the rod. So I'm going to have a look behind the clutch and see if the ball is actually in there.
On a side note. I was sent the wrong piston dust seal for my caliper. So waiting on the right one to be sent. Oh the joys of online shopping, where you cant take the original part in to compare.

Got round to checking behind the clutch for the ball bearing. It is there. I was kinda hoping it wasnt, so that when I put one in, it would hopefully make the actuater closer to the pushrod. So not sure what to try next.

Here's the instructions in English (somewhat).
www.cybike.co.uk/Portals/0/Documents/72-...017-04-21-123150-447

Thanks for that. It has been (somewhat) helpful. I was screwing the slotted screw all the way in. But its saying I have to unscrew it a certain amount to take up the slack between the actuater and pushrod. Which is ass about face to normal. Might make all the difference. I'll let you know. Cheers.

If i remember correctly, when i installed my PMC easy clutch with the PMFR clutch plate i ended up having to make a new actuator rod about 10 mm longer out of stainless, it was fairly easy to do.

Well, I spent another couple of hours trying to sort this Easy Clutch out. I thought I had made some headway. I backed off the stotted adjuster screw till it couldnt go anymore (about 2 full turns). It felt like the actater was engaging the pushrod and there was no slack. So I screwed it in half a turn. Still felt good. But after pulling in the clutch a few times, there was a click sound and limp cable. Screwed the adjuster in and then back out and I was back with a tight cable.. Tried many different settings on the adjuster from all the way in to as far out as it would go. But still ended up with the dreaded click and limp cable. Even with minimal clutch travel. It ended the same after 4-5 pulls of the clutch. Starting to seriously think about finding someone to put the actuator arm from the Easy Clutch onto my standard Z1 clutch actuator. But hate the thought of wasted NZ$170.
I'd like to thank everyone for their input and suggestions. But I'm about done with this and will go back to standard. Cheers.

What about the clutch lever or perch. Are they factory? Somehow your getting to much travel. After your final adjustments do you have about an 1/8-1/4” free play in the lever before you feel resistance?

The clutch lever and its holder are all factory. Yes. No matter if I have 1/8" freeplay or an inch with minimum travel of the pushrod. It lets go. I did notice that the Bearing Holder doesnt sit square to flat bit in the gold main body and its only just being held in place. I wonder if thats got something to do with the problem?