I have two 2005-06 Kawasaki Ninja ZX6R 636s.
One is fully race-built, but came with normal weight springs. The levers are CRG adjustable foldable levers..
The other is street legal, but I rebuilt it from the ground up after 2 years of owning it. With the rebuild came the EBC racing clutch kit that included the stiffer clutch springs. The levers are just adjustable foldable shorty levers from ebay.
The street legal one has always had a heavy clutch pull weight. After I got the racebuilt one earlier this year, I noticed there was a good difference in clutch pull weight.
With everything greased (cable, clutch parts, levers, perch, basically anything that moved or could cause resistance) I measured the pull weights (lb-force) required to full pull in the clutch using a digital hang scale. The street bike measured at 20-22lb-force, the racebuilt bike measuered at 14-16lb-force.
I swapped the racing clutch and springs into the racebike after noticing this, because anytime I ride for more than 30 minutes my hand gets tired on the street. On track its fine.
This only changed the pull weight slightly on both bike. Realistically the stiffer springs are only noticeable while riding, mainly off the line.
Because of this, I again cleaned & lubed the clutch cable, greased all the clutch parts, ground down the ebay levers, cleaned and greased all lever parts, and even the lever perch parts on the street legal bike. The racebuilt bike I did the same minus the grinding of any lever.
After all that, I measured both bikes again. The racebuilt bike measured (with stiffer springs and above mentioned cleaning and greasing) at 16-18lb-force now, and the street bike still read higher at 18-20lb force required to fully pull in. I even tried swapping levers on both bikes, with no change at all in readings
Trying to figure out if this is normal for the 05-06 636, or if there's something internally that is causing this on the street bike. My only options short of going internal to the engine now is to either increase mechanical advantage and modify the lever itself, or buy and ez pull to also increase mechanical advantage.
One is fully race-built, but came with normal weight springs. The levers are CRG adjustable foldable levers..
The other is street legal, but I rebuilt it from the ground up after 2 years of owning it. With the rebuild came the EBC racing clutch kit that included the stiffer clutch springs. The levers are just adjustable foldable shorty levers from ebay.
The street legal one has always had a heavy clutch pull weight. After I got the racebuilt one earlier this year, I noticed there was a good difference in clutch pull weight.
With everything greased (cable, clutch parts, levers, perch, basically anything that moved or could cause resistance) I measured the pull weights (lb-force) required to full pull in the clutch using a digital hang scale. The street bike measured at 20-22lb-force, the racebuilt bike measuered at 14-16lb-force.
I swapped the racing clutch and springs into the racebike after noticing this, because anytime I ride for more than 30 minutes my hand gets tired on the street. On track its fine.
This only changed the pull weight slightly on both bike. Realistically the stiffer springs are only noticeable while riding, mainly off the line.
Because of this, I again cleaned & lubed the clutch cable, greased all the clutch parts, ground down the ebay levers, cleaned and greased all lever parts, and even the lever perch parts on the street legal bike. The racebuilt bike I did the same minus the grinding of any lever.
After all that, I measured both bikes again. The racebuilt bike measured (with stiffer springs and above mentioned cleaning and greasing) at 16-18lb-force now, and the street bike still read higher at 18-20lb force required to fully pull in. I even tried swapping levers on both bikes, with no change at all in readings
Trying to figure out if this is normal for the 05-06 636, or if there's something internally that is causing this on the street bike. My only options short of going internal to the engine now is to either increase mechanical advantage and modify the lever itself, or buy and ez pull to also increase mechanical advantage.