ETZ

ETZ - Right foot gear change conversion

Due to an accident back in 2009, I no longer have a left foot which works as it should. This means any motorcycle I ride either has to be right foot shift, automatic, or have some kind of hand change. I successfully converted my Kawasaki Drifter to hand change by running a cross over shaft under the petrol tank and linking it to the existing left foot gear lever. This works well but because your right hand is operating the gear lever, it can't operate the throttle at the same time - this results in some rather clunky down changes. The ETZ presents a few problems - the main one being a lack of frame to bolt anything to. Time for some creative thinking.

Plan "A"

Idea number one was to make a left hand twist grip which would rotate similar to the throttle, and by means of two cables, operate the gear lever. Very much like the system used successfully on scooters for a few years now. First of all I obtained a "push - pull" twist grip and modified it so that a clutch lever and all the switch gear could be mounted on it. A one inch diameter tube fitted over the existing ETZ handlebars and rotated freely. The clutch lever and the switch housings were both machined out to fit one inch handlebars.

Most of the bits necessary to make a hand operated gear change.

The roller which is turned by the twist grip - and hopefully moves the gear lever.

Here it is all fitted and working. Note I didn't say working well.

For the engine end of things, I thought some kind of wheel which would be turned by the two cables, and in turn would operate the gear lever. Now being a lift engineer, I just happened to have an old door hangar roller which seemed to fit the bill. Just about the right size and it already had a bearing in the centre. A couple of rose joints and a length of 6mm threaded rod and the job was done.

I love it when a plan comes together - or not, as the case may be.

Twist twist, pull pull, push push, turn turn, change, change. Or something like that,

"Well - did it work ?"

Yes and no. Yes - in as much as when you twisted the twist grip it would indeed change up and down the box. No - as in the amount of movement needed at the handlebar end was excessive, but if you altered the ratio of twist grip movement to gear lever movement to give less "twist", then it was physically too hard to operate. This needed a bit more thought.

Plan "B"

Now if my hand can't do the job, then maybe my right foot can. Plan "B" was to make some kind of cross over shaft and operate the gear lever from the other side. Now I noticed the ETZ carries the centre stand on a nice, useful looking tube - just the sort of tube needed for a cross over shaft.

Let's try going under the engine.

It should look something like this - if it works.

This idea was fine until it came to other side of the engine. There was no practical way of avoiding the centre stand return spring, and it was difficult to get around the shape of the engine.

Well if the shaft won't fit underneath, what about above ? There seemed to be enough room for a shaft to pass beneath the carburettor. As for mounting it - I already had a hole in the oil pump cover so that could be used to support the shaft on the left hand side of the engine - I can worry about the other side later.

Right - this time we try going over the engine.

Now this is looking promising.

That's how to attach it on the left hand side.

Whilst looking around for something totally unrelated to this job I picked up an old plastic conduit saddle - that looks just the thing for mounting the cross over shaft on the right hand side of the engine. I knew a plastic saddle would melt, but I also knew I had some steel ones somewhere. I placed the saddle where it needed to be fixed and marked the holes - in another twist of good fortune the holes could not have been better placed if you had designed it that way - one hole either side of the strengthening web of the alternator cover.

That's how to attach it on the right hand side.

Sometimes things just slot into place.

Right - that's the cross over shaft fitted. Time to make a couple of brass bushes for it to run on, then weld the operating arm to the left hand end of the shaft. The right hand gear lever which fits on the other end must be removable otherwise there's no way to fit it unless you remove the carburettor to allow the shaft to pass beneath. Anyway - all the bits were now ready to fit.

Thankfully I was a toolmaker before I was a lift engineer - many thanks to Ian for the use of his lathe.

A D.I.Y. right foot shift kit.

The whole plot, fitted, looks something like this.

Both gear lever and brake on the right hand side. Let's try not to get 'em mixed up.

The linkage which operates the existing left foot gear lever.

Before you start moaning - it was painted up following this photograph being taken.

"Well - Did it work?"

So far, yes it does, but the bike isn't actually on the road yet, so I can't really say how successful this conversion has been. As soon as I get the log book sorted out, and the bike insured, taxed and MOT'd, then I'll updated this page and let you know.

January 21st, 2014 and I rode the bike all of six miles over to the MOT tester . . . it passed. Did have a problem on the way back, but that was due to a dirty fuel tank. So far the right foot shift is working well. The clutch is dragging a bit so finding neutral from a standstill is tricky, but I expect the clutch will free up a bit once the bike gets a bit more use, I mean, it had been standing for a good few years. As soon as I get some tax on it, I'll take it for a proper shakedown run.