Hydraulic clutch linkage - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 17 Old 05-13-2015, 01:18 AM Thread Starter
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Hydraulic clutch linkage

I just completed modification #106 on this bike which is the installation of an EBay hydraulic clutch linkage.

A fairly simple installation, all things considered. I have an Africa Switch and mirror relocation which required digging out a spare rear bar clamp. I made a mock-up bracket to mount the slave cylinder, then made one from steel stuck together with my MIG.

I'm unable to post photos so here is the Dropbox link if anyone is interested in the setup. The pull effort seems a bit lighter and smoother but will wait until Mikes bike is side by side as his levers are also well serviced and make an accurate comparison.

https://www.dropbox.com/sh/b6typ8ue8...mAZbE0S0a?dl=0
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post #2 of 17 Old 05-13-2015, 02:15 AM
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That's pretty slick, Norm. Did you take any detail pictures of the fabbed bracket for the slave?

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post #3 of 17 Old 05-13-2015, 10:56 AM Thread Starter
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I want to paint it so will have to pull off again. I'll try to remember to do a sketch & trace a template.

It wasn't difficult to make since it is just a flat plate, not so much. I used a flat piece of bracket material from the junk box, and a piece of steel tubing. The bracket was cut to length and bent upward into a short "L". The tubing was welded to a notch in the upward bend to act as the mount for the threaded shank on the slave cylinder. A pair of nuts provide some adjustment of position.

I positioned the bracket and slave to determine alignment, then marked position for a 6 mm nut to be welded to the end of the bracket. This nut drops over the locating pin which is cast into the side case.
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post #4 of 17 Old 05-13-2015, 12:50 PM
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That does look good! And no more cable to break

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post #5 of 17 Old 05-13-2015, 05:43 PM
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Interesting and well-done project, Normk. I've never experienced a hydraulic clutch in anything except a 4-wheeled vehicle.

How does it "feel?" Is there like a definite point/sensation of engagement? And is there any way to adjust it for preferred free play?



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post #6 of 17 Old 05-13-2015, 11:32 PM Thread Starter
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The lever effort seems to be less + the feel seems a bit better but will have to wait until Mike visits to compare since his levers are well serviced and give the same performance as did mine originally. I'm not certain that the system will be more reliable than the cable but interesting to try the conversion. I haven't measured the piston diameters but will try to get a sizing with the master in place and since have a spare slave, it will be easier to measure.

Someone mentioned the exhaust heat issue which is a concern and will check to see how that pans out.
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post #7 of 17 Old 05-14-2015, 10:28 AM
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Normk,
May we ask you measure the clutch pull effort of both systems?
And maybe try to gauge the 'notchyness' of release or lack thereof?

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post #8 of 17 Old 05-14-2015, 06:23 PM Thread Starter
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It seems smoother on engagement/slipping than before. FWIW, I used an ATV cable which is heavier and smoother than the stock KLR cable. When Mike is next here, of if take it down to visit him, I will try to compare his lever as the two clutch actions seemed virtually identical.
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post #9 of 17 Old 05-15-2015, 07:43 AM
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Very cool setup. I wonder how an extended clutch arm would work with the hydraulic clutch rig? Best of both worlds?
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post #10 of 17 Old 05-15-2015, 11:07 PM Thread Starter
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Next time Mike is here, I'm certain that he will be interested in trying his extended clutch arm with my hydraulics. I'm not certain that there will be enough stroke but it will require testing to see.

I will try to ride it a bit more in order to develop impressions. I've backed off the adjustment twice as was having some slip at heavy throttle because its more difficult to assess slack and trying to maintain adjustment with minimum slack.


FWIW, the slave cylinder bore is 11 mm, master seems to be bigger but I don't think I'll pull it apart to measure. I've contacted the vendor to see if they have information. So far it seems positive but have to say that the longer clutch arm is simpler, although ironically more expensive.


Quote:
Originally Posted by twinjet View Post
Very cool setup. I wonder how an extended clutch arm would work with the hydraulic clutch rig? Best of both worlds?
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