EZ Pull Clutch DIY - ZX6R Forum
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  • 3 Post By PainfullySlo
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post #1 of 9 Old 03-09-2016, 01:15 PM Thread Starter
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EZ Pull Clutch DIY

I'm a sucker for DIY and I was looking for a way to modify my own clutch to make it easy pull.

I came across the post from bridge9 on a Stunt Bike Forum forum.

I was wondering if anybody has every done anything like this and how it turned out/held up....

DIY easy pull clutch - Stunt Bike Forum

hi guys, not sure if this subject has been covered here before? but if not here we go. I just got myself a 1998 cbr 600 stunter! I've never stunted before so I have a long road of learning ahead!! especially at the age of 44!!!! but I can wheelie a little bit and do rolling burnouts! so that's a start anyway the one finger clutch on the bike feels a bit stiff for me so after a little research I came across an easy pull clutch leaver and decided to turn my one into an easy pull myself. first the tools



a drill bit which should be a tiny bit bigger than the head of your cable.
first you drill a new hole a few mill closer to the pivot point of your leaver.





my leaver had a big hole already there so I had to drill into that with my drill bit. it looks a bit messy because of this. there was enough metal there for me to drill my new hole.
next you use a small filing bit, these come with most hobby/craft rotary tools. make sure it's a bit bigger than the width of your cable so the cable will not be tight when fitted. you make a new channel to the new hole. make sure you go deep enough.



then using the same bit you make the channel in the front of your leaver deeper. you have to do this a bit at a time and keep trying it on the bike to make sure the cable isn't being bent of strained too much. it's trial and error.




nearly there! the next thing is to make a bit more room in the leaver bracket. use the same filing bit and file the hole deeper. same as before keep fitting it to the bike and trying it.



and the last bit is when you fit it all back together make sure you turn the opening in the cable adjuster to line up with the new channel in the lever bracket, if you don't the cable will eat into it a wear away and break quicker!


this pic was taken before the work, as you can see the adjuster is in the wrong way for the new conversion.. so make sure you turn it the other way round so the cable can go through the gap in the adjuster and run in the new channel you made in the lever bracket!
my clutch now feels about 80% easier!!! I didn't think I would get such a good result by moving the hole a few mill!
hope this can be of help to someone!!
oh and p.s. any stunting tips for a beginner welcome!
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post #2 of 9 Old 03-09-2016, 02:00 PM
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You are increasing the mechanical advantage of the lever by doing this mod.

If you are ok with drilling holes into your bike then the logic behind this is sound.

My advice, if your clutch is too difficult for you to actuate, follow this process:

1) lube the cable. Many times a difficult clutch can be the result of a dry or frayed cable. Make sure that the cable is in good working order and it moves easily and freely when disconnected.

2) lube the pivot points. Both for your lever and the pivot on your clutch housing. If it moves, put lube on it.

3) change levers. OEM levers kind of suck for leverage, as dumb as that sounds. Make sure that you are using a full length lever and not a shorty to give you increased leverage.

4) If that still does not do the trick, use this:
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post #3 of 9 Old 03-09-2016, 02:14 PM
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Yes, you'll be increasing the mechanical advantage but also realize you'll be reducing the amount of cable pull.
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post #4 of 9 Old 03-09-2016, 02:28 PM
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Quote:
Originally Posted by trackdayhero View Post
Yes, you'll be increasing the mechanical advantage but also realize you'll be reducing the amount of cable pull.
This.

With this mod I would be very careful that your clutch is fully engaging/disengaging. If it's not, you will either have clutch slip on power, or clutch slip when you have the lever pulled right in. Both are very bad.

Personally I would stick to longer levers and the increased throw that goes with them, if you want an easier clutch.

The only other safe option I can think of is getting something assisted (i.e. a hydro clutch with a vacuum/electric powered booster). Even then, there is a downside - less 'feel' when it engages.
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post #5 of 9 Old 03-09-2016, 02:51 PM
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Quote:
Originally Posted by Erelyes View Post
This.

With this mod I would be very careful that your clutch is fully engaging/disengaging. If it's not, you will either have clutch slip on power, or clutch slip when you have the lever pulled right in. Both are very bad.

Personally I would stick to longer levers and the increased throw that goes with them, if you want an easier clutch.

The only other safe option I can think of is getting something assisted (i.e. a hydro clutch with a vacuum/electric powered booster). Even then, there is a downside - less 'feel' when it engages.
You can actually go with lighter springs in the clutch to make the pull easier but then you run into the possibility of clutch slippage.

The short version is: grow stronger
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post #6 of 9 Old 03-09-2016, 04:03 PM Thread Starter
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Thank you everyone, for the feedback. As usual, there are super important points that I didn't think of. I don't want to jeopardize my safety so maybe I'll just do the grow stronger option
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post #7 of 9 Old 03-09-2016, 05:09 PM
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A used perch and lever are cheap. You can get one and try this out it see what you think. If you don't like it or find that it doesn't work as expected, you can just put your old perch and lever back on.
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post #8 of 9 Old 03-09-2016, 05:18 PM
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Do you have shorty or long/oem levers? Long take less effort. I'm never buying shorty again, I'm just going to go with custom long levers.
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post #9 of 9 Old 03-09-2016, 07:29 PM
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How about getting those CNC aftermarket levers that have the adjustable knob. Chances are, you are having issue with the pull because of the lever distance. The aftermarket ones allow you to adjust the lever position closer to the handle so you can grip it better while not effecting the tension of the cable.

You can check out PainfullySlo's levers:
https://madscientistmoto.com/product...s/kawasaki/zx/

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