I started work on my hydraulic clutch conversion today. My original worm gear clutch actuator is broken and I didn't want to spend a lot of money to replace it with a sub-standard aftermarket one. I picked a used clutch master and slave cylinder on eBay for $40 plus $15 for shipping. They are from a 95 Kawasaki ZX9R and very similar to the ones on my Concours 1400. They will both need new seals but all the parts from Kawasaki come to less than $100 and it will be all genuine factory parts, not aftermarket stuff.
The slave cylinder nose is just about the same size as the opening for the chrome cap that fits in the cover on stock bikes at 37mm. I bored the original hole to fit the slave with .004" clearance.
No going back to stock now!
To allow the slave to sit as flat as possible I mounted it on my rotary table and milled off the protruding flange area on one side.
The surface of the cover is not flat and the bolt hole ears of the slave were elevated from the surface so I milled a flat area large enough for the slave to fit flush and flat. It required removing .060" of material but the cover is quite thick in this area. I used a transfer punch to locate the bolt holes and drilled and tapped them to 6mm. I oriented the slave to give a good angle for the hose to run forward and up the left frame tube.
The I did some measuring to figure out the length of the pushrod. I bought a 3' length of 5/16" tool steel rod for this and I came up with 10.5" as the correct length. After I'm sure it's right length I will harden the ends to prevent wear.
Good thing I took the slave apart as the seal was split in half.
I did a little more work on the mill to make the slave look better and also removed the 2 lugs that prevent hose rotation. I mocked it up with the hose from the Buell front brake and it will work well with a straight end on that end of the hose. The hose needs to be 50" long, I'll get that and the Kawasaki parts ordered tomorrow.