NB: These instructions are given for guidance only and cannot engage the author's liability in the event of misinterpretation, failure to assess the vehicle's actual condition and/or non-conformity, unsuitable mechanical practice or the use of inappropriate tools.
Fitting the Easy Clutch kit (clutch-lever extension)
- Drain the engine oil.
- Unhook the clutch cable from the engine-side lever.
- Put the gearbox in neutral, remove the selector.
- Remove the selection cover, carefully noting the position of the washers, O-rings and selection spring.
- Remove the selector drum.
- Remove the clutch cover and clean it thoroughly.
- Remove the clutch lever and the 8 mm ball.
- Check that the clutch pushrod protrudes from the layshaft by about 11 mm. If not, check the length of the pushrods (123 mm for cable-operated 1000/1200, 112.5 mm for 750) and the condition of the balls. If these are correct, check the clutch-plate thickness. Replace the balls if damaged.
- Fit the Easy Clutch lever (feeding it through the inspection hole) and the 8 mm ball, with a little grease at the contact points.
- Fit a new gasket and refit the clutch cover. Do not overtighten: torque 8-9 Nm.
- Refit the selector drum aligning the marks, then the selection parts, washers, O-rings and selection cover (new gasket). Turn the rear wheel by hand to check the gears engage.
- Fit the supplied cable-outer stop with the supplied M8 screw, aligned with the clutch lever.
- Hook the cable to the lever with the supplied cable clip. Start with the highest position (normally correct with a clutch in good condition and properly set). Set the free play (about 1 mm at the lever). If the plates stay slightly stuck when fully disengaged, use the lower position on the Easy Clutch lever. If the clutch still drags, a component is faulty or out of tolerance and must be corrected.
- Refill with fresh oil to the max mark.
For a heavy clutch action, the Easy Clutch softens the action if everything is in good order, but will not cure a fault: see the fiche "Causes of a heavy clutch action" (lubricated cable and outer, lever without play, aligned plates, sound drum splines, straight pushrods of correct length, spherical balls…).