Started work on a hydraulic clutch conversion for the Benelli yesterday. Found the old slave from my RSV and tried to make it fit.
Started with a bit of manky looking alloy plate I dug out of my workshop.
Stuck it on my (old and very knackered) lathe:
Made a tool to ensure perfect alignment of the slave and clutch pushrod...
...which fits like this
The 8mm plate wasn't thick enough, ideally I would have used 12 or 15mm plate, but you use what you have. To make up the additional clearance I modified the original RSV spacer:
And it all fits together like this. The 8mm drill bit is actualy part of the alignment tool, and simulates the clutch pushrod.
To remove the excess material, it's back to the agony of chain drilling and hours of filing:
The final adapter plate:
Bolted onto the gearbox (countersunk hole missing in this pic):
And finally with the slave in place:
Unfortunately the slave has to sit at an angle to prevent the mounting holes clashing with the gearbox mounting lugs, so bleeding might be a challenge. I'll remove the slave to bleed it if required, it's only three bolts.
Next job is to make a longer clutch push rod, and route the hydraulic hose up to the master cylinder (using a 2007 Fireblade MC).