Here's how to make your clutch pull easier

I just did this. Thought you might be interested.
Take off the side cover where cable goes in.
Remove the actuator thingy that the cable connects to.
Cut the arm in half.
Weld in a piece of steel to make the arm about 4mm longer. This gives you more leverage and an easier pull.
Grind some aluminum off the inside of the cover to give the cable a bit more clearance so it won't rub (see the shiny spot on the following photos).

I also brazed the spot where the arm is pressed together just for the heck of it (extra strength).

I'll post photos next. It ain't pretty but I really like the improved feel. It's not a huge difference, but very noticeable.

Post edited by: Nelson, at: 2006/10/13 02:03

remove this

arm before cut

arm after cut.

It doesn't look much longer in the photo, but it is an extra 4mm. The shiny spot in this pic is where I ground a little off to make more clearance for the cable.

IMPORTANT! I should have said earlier. Take the actuator apart before welding otherwise you'll burn up the rubber seal inside it. There's some loose ball bearings in there, so don't lose them on the floor!
Good luck.

My bike is a 78 kz1000A

If you guys like this, I can start posting other how to's also.

Post edited by: Nelson, at: 2006/10/13 02:02

Nelson, how to's around here are always helpful, keep em coming. I've never found the clutch lever pull to be objectionable on the KZ's but then I suppose I'm used to it. My former boss was checking out my Z-1 Classic and he made a comment about the clutch pull being much stiffer than his bike but he rides a Honda Valkerie with a hydraulic clutch. I guess it is all in what you are used to.

I was poking around on Klasmo the other day, and found a hydraulic clutch kit for the KZ. If you really wanted to go for the easiest pull, that would probably be it.

i just dont use the clutch,much easier that way! :evil:

how do you do that?

...inquiring minds and all that.

I think I saw an aftermarket piece that used the same idea, it was just longer like what you did.
I only use the clutch for 1st and gearing down:evil:

I dropped a greased up ball bearing in there 2 years ago for easier clutch pull.