New clutch setup won't disengage

Your hind parts are still smoking a little bit, YR :D
You can't make the pedal easier and the throw shorter at the same time, if the clutch is moving the same amount or more!

Bigger master piston makes the pedal harder (and a shorter stroke for the same amount of TO movement). Since my pedal stroke stays the same, and the slave will move farther (which is what I need), the pedal is harder at full deflection.

Conversely, smaller master piston makes the pedal easier (and requires a longer stroke to move the same amount of fluid at the same pressure). Again, my pedal stroke stays the same so the pedal is easier - but the slave won't move as far. That's why it's easier.

Anyhow, the pull cylinder currently attaches to the same fork hole where the original Z-bar rod did. The only difference is that it's pulling from behind the fork instead of pushing from in front of it. I do have the round-nosed spacer for the rod, but that won't help with a new hole since it won't be countersunk and I may not be able to get to it with a big drill from the front.


Unreal.
Yup. A smaller bore makes it easier to push with longer travel. That's why when I convert from power to manual brakes you use a smaller diameter piston.

Damn the crack pipe.

BTW. If you move the hole in on the fork, it can't be the same sized hole as what's there. It will have to be smaller. How small can you make it? A 1/2 inch move will make a big difference.