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ZZR1400 engine - master cylinder size


Erazor

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Hi, Just joined the forum and need help. I have put a Kawa ZZR 1400 engine into a Bond Bug. The existing Kawa clutch lever has a tiny reserviour and a very small piston to operate it. How do you guys work out the correct piston size needed when converting it to a pedal box operation? The standard brake master cylinder bore on a Bug is 1 inch and an eight.

Obviously a lot more leverage as well with a foot and a pedal. How do I work out what to use for it to work correctly ?

 

 

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I wouldn't attempt to try and calculate it, too many variables and would probably be wrong.

Reliant clutch master cylinder should be 5/8" bore (16mm). I would start by piping that up as it is and see how the clutch feels. I suspect you will be able to easily disengage the clutch with only partial pedal travel due to the large bore and the clutch should be light because the spring in a bike clutch will be weaker than a car one.

You need to see if full pedal travel is overloading the slave cylinder and if it is, either get a smaller bore master cylinder (think 5/8" is already the smallest Girling do) or move the pushrod connection closer to the pedal pivot point.

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If you are you intending to use the existing slave cylinder looks like you have a problem with using a standard pedal master cylinder. What you need to know is how much movement the clutch requires, then measure how much movement your existing 5/8” master cylinder has. It’s a simple ratio calculation then ie. if your master cylinder moves 1” then a 5/8” slave will also move 1”.

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