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#140663 - 02/12/18 10:01 PM Adjustable clutch/brake levers?
Wallhopper Offline
Junior Member

Registered: 04/06/15
Posts: 12
Loc: Dorset ,UK
Hi Everyone.

Just wondering if anyone knows if there are adjustable levers available for the xt225?

I want to bring the levers in closer to the handlebar as the clutch/brake is nearly on my maximum reach. I have already bought levers with more of a dog leg which has helped.

Was thinking of maybe heating and bending the levers in, but I'm thinking this would make the levers weak. Has anyone done this with success?
Or has anyone modified to a different lever?

Thanks in adavance

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#140666 - 02/12/18 11:01 PM Re: Adjustable clutch/brake levers? [Re: Wallhopper]
patuca Online   content
Bronze Member
*****

Registered: 08/18/12
Posts: 548
Loc: Cranbrook BC Canada
A quick trick is to slacken the cable so the lever is slack then cut a thin spacer from a piece of plastic tubing (gas line etc but hard plastic is better) say 4 or 5mm thick.

Slice one side of the spacer (washer) so it fits over the cable when it's exposed between the perch and the lever. Trim the washer thickness so when the brake is adjusted the washer will hold the lever away from the perch and the lever will be closer. Be careful you still have enough lever motion when you really need to squeeze.

I've seen some mods where the lever or the perch is drilled for an adjustable set screw that holds the lever face away from the perch and will keep the lever from closing completely.

There are adjustable levers but last time I looked they were rare it might take some searching.

Good levers are malleable and will bend cold in a vise but it's an expensive experiment on new levers. It might be worth trying on some used ones but only on the long part of the handle. Heating alloy to bend it is not a good idea...

Just some shots....

patuca


Edited by patuca (02/12/18 11:03 PM)
_________________________
"this will only take a second..."

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#140673 - 02/13/18 12:58 PM Re: Adjustable clutch/brake levers? [Re: Wallhopper]
peejman Offline
Platinum Member
*****

Registered: 06/03/13
Posts: 2733
Loc: East TN USA
The factory levers are adjustable, there's an adjustment screw near the pivot. There's a 2nd adjustment for the clutch cable about half way along the length of it, typically near the carb.

In my experience, moving the levers in close to the bar tends to reduce the travel to an extent that affects function. Meaning... if you set the clutch lever close in to the bar, you won't be able to fully disengage the clutch when you squeeze the lever all the way in.

Similarly with the brake, if the lever is close to the bar, you'll limit your braking force and won't be able to apply maximum braking. Given how crappy the stock front brake is already, that's a pretty scary concept.
_________________________
This shall pass, be still and know.
2006 XT225, UNI filter, ProTaper bars, MSR handguards, SS front brake line, Shinko 241's.

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#140677 - 02/13/18 04:33 PM Re: Adjustable clutch/brake levers? [Re: Wallhopper]
#brer15 Offline
Member L2
*****

Registered: 10/03/16
Posts: 243
Loc: Atlanta,GA
^ Those adjustments only adjust the freeplay, they don't actually move the levers closer to the handlebar when they are disengaged.
_________________________
2004 XT225 purchased new in October 2004 0 miles. Current miles over 27,000.

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#140680 - 02/13/18 05:15 PM Re: Adjustable clutch/brake levers? [Re: Wallhopper]
#brer15 Offline
Member L2
*****

Registered: 10/03/16
Posts: 243
Loc: Atlanta,GA
I saw one on Amazon. Adjustable clutch lever, from Motion Pro part# 14-0405. The only problem is, in the picture they show 4 levers, only one of which is adjustable. May be worth looking in to, maybe send in your question. The companion brake lever is part# 14-0506. Sorry I cant figure out how to put a link up to it.
_________________________
2004 XT225 purchased new in October 2004 0 miles. Current miles over 27,000.

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#140703 - 02/14/18 05:27 PM Re: Adjustable clutch/brake levers? [Re: Wallhopper]
Wallhopper Offline
Junior Member

Registered: 04/06/15
Posts: 12
Loc: Dorset ,UK
Hi,
Thanks for the replies, I'm planning on giving your advise a go at the weekend, and I'll check out the motion pro levers. Hopefully there available in the UK.

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