TOPIC:

Hello mate.

See below for clutch conversion.

BILL..........YOU MAY WANT TO MOVE THIS POST TO ANOTHER PLACE ON THE SITE FOR OTHERS TO ACCESS ????


Its one of the best mods for a Z1300 as the they are famous for snapping cables due to the sheer size of the clutch & the strong springs. It makes the clutch much lighter & adds feel.
You need a ZRX1100/1200 or ZZR1100/1200 master cylinder & slave cylinder too & a length of fluid line the same as your clutch cable.
Its quite a cheap job if you do it properly.


You need to make the plate yourself from 6mm alloy plate.
The hole for the slave cylinder needs to be 43mm diameter & 6 mm from the outer edge.
Once you have it made just offer up the original cover plate with the 3 holes in it and mark it for position of the 3 holes.
Do the same with the cylinder once in the 43mm hole.

I once had a number made & sold them on Ebay but some people just could not understand how to carry out the work & I spent hours on the phone or emailing people........so stopped after that !

1 X PLATE
1 X M6 BUTTON HEAD ALLEN BOLT.
1 X M6 NUT





PLEASE ENSURE THAT YOU FIT THE M6 BUTTON HEAD ALLEN BOLT PROVIDED IN THE KIT THROUGH THE PLATE FROM BEHIND AS SHOWN IN THE PICTURE BELOW. IT MUST BE FITTED THIS WAY TO AVOID CONTACT WITH THE CLUTCH CASING.





BELOW IS AN OUTSIDE VIEW OF THE PLATE WITH SLAVE CYLINDER FITTED.
YOU WILL NEED TO FIND ANOTHER M6 BOLT TO GO THROUGH THE HOLE THE ARROW IS POINTING TO, AND AN M6 NUT FOR THE BACK.





ONCE BOTH M6 BOLTS AND M6 NUTS ARE TIGHTENED, YOU NEED TO OFFER THE UNIT UPTO THE SIDE OF THE ENGINE CLUTCH CASING, MAKING SURE YOU HAVE THE SLAVE CYLINDER DIRECTLY INFRONT OF THE TOP OF THE CLUTCH ADJUSTER BOLT. YOU MUST FIRST REMOVE THE ORIGINAL SMALL CABLE LEVER FROM THE ADJUSTER BOLT AND ADJUST IT AS DESCRIBED IN THE KAWASAKI MANUAL BEFORE YOU FIT THE UNIT.






ONCE THE UNIT IS FLUSH ALL AROUND WITH THE ENGINE CLUTCH CASING, YOU THEN INSTALL THE FLUID LINE, HANDLEBAR MASTER CYLINDER AND BLEED NIPPLE, THEN BLEED AS YOU WOULD A NORMAL BRAKE SYSTEM.

No more sitting at the side of the road with a snapped clutch cable !!

Pete F

8th FEB 2014 UPDATE.

Got the bike fully assembled & started yesterday.

It started pretty much first hit which is always a good sign.

Small leak from one of the exhaust gaskets (used copper rings from kit) which are crap. Better using the metal & crush material type.

Ran it upto full temp & had no leaks or issues.

Next remove cam cover & re-torque head studs & replace the 6 exhaust gaskets.

Paintwork is just about ready from paint shop so all coming together !

Pete F

How does it feel ?

It feels great.

Its such a lot of intense work & in my case over a good few months (due to lack of time away from work) so when it all comes together & the result is good.........it feels good !

Just wished it was end of March or early April so I could get it on the road.

Roll on spring !!

Pete F

Nice one Pete - good on yer. Great to hear that it is coming together.

Pete F, Thanks for the Subaru sump plug tip. Got mine yesterday