Adjustable clutch and brake lever

[ersigh]

Anyone adjusted their clutch cable yet? Anyone had problems with their clutch not disengaging??

I adjusted my clutch to what the manual said, and my not disengaging problem got worse ...

I suspect this is the issue w/my bike starting ... cuz if it's in neutral, it usually starts fine.

[dnakase]

Also make shure the electrical conenction to the clutch switch is snug.

You can't start if the signal from the clutch switch isn't getting through.

[rick77f]

Recheck your adjustments on the bottom left of the bike. The adjuster nut and retainer could be too tight. Does it retract slowly? Also when you are down there check for dirt or grime.

[ersigh]

It's been adjusted according to manual spec.

it made things worse.

[voodoo1694]

can someone tell me how to adjust the brake and clutch levers forward. the previous owner of my bike must have had pretty large hands. Thanks.

[Setter32]

The brake lever is easy.................there's a knob or disk......right on top of the lever......and I think with #s on them.........just adjust that knob until you're happy with the position.....

The clutch lever is a little bit diff................there are 2 knobs or disks........on the cable.....near the top to the lever.........

....one knob is to adjust.........the other is to lock it in place.........

....am I being to vague?........

...If someone can show it to you in person.........I think it would be alot easier for ya........


:D

[linp]

The brake lever should be pretty self-explanatory. Move the brake lever outwards, and turn the dial to a smaller number. (OEM style SV650/S Lockhart Phillips adjustable brake lever 240-1258 $3.95)

The clutch... well, you could change the friction zone by adjusting the cable slack. Loosen it a bit at the adjusters on the perch. If that still doesn't do it for you, there are aftermarket levers (http://www.mxsouth.com/asv/asvlev.htm) ($) you could install that looks like the brake lever side. (OEM style SV650/S Lockhart Phillips non-adjustable clutch lever 240-1223 $4.95)

Clutch cable play adjustment:
• Loosen the locknut and turn the adjuster into the clutch lever assembly.
• Remove the engine sprocket cover.
• Loosen the locknut and turn out the adjusting screw two or three rotations.
• Position the clutch release lever as shown by turning the locknuts.
• Tighten the locknuts.
• Slowly turn in the adjusting screw until resistance is felt .
• Turn out the adjusting screw 1/4 of a turn, and tighten the locknut.
• Turn in or out the cable adjuster to obtain 10 - 15 mm (0.4 - 0.6 in) of free play at the clutch lever end .
• Tighten the locknut.
(Clutch cable play: 10 - 15 mm (0.4 - 0.6 in)

[cyclox]

Any suggestions on obtaining adjustable clutch and brake levers for a '99 SV650? I'm finding the reach to the stock levers a little far for my set of hands. Since I can't get a new set of hands (for a reasonable amount of cash), I figured levers would be easier...

thanks!

[Cooker]

Anybody have a recommendation for an aftermarket adjustable clutch lever?

Any good or bad experience? stories?

I searched on the web, but most finds were for racing or dirt, and I'd like to avoid the imperfect match installation; I'd rather not do a "cut to size, hammer to fit" :eek: mod.

--I've heard that Lockfart-Phillips parts never quite fit. Anybody buy and install one of those?

[nols]

I am currently having problems my clutch.

I have a 2003 model year Suzuki SV650s with about 500 miles on it.

The first and most major problem I am having a currently noticed within the last 100 miles. The engagement of the clutch only seems to be happening with in quarter inch after there is resistance in the clutch lever. By this I mean that when I pull in the clutch lever till there is a. resistance I only can pull in additional quarter inch before the clutch is fully disengaged. This is becoming a problem because I hardly have any friction zone to use. I am having difficulty from the small amount friction zone when taking off slowly from a complete stop. I'm wondering what I have to adjust to have a larger friction zone.

The second problem I am having comes from having my bike knocked over on its left side. The problem when the bike was knocked over the clutch lever was forced down a quarter inch or so. When I have the clutch lever fully pull in I have a quarter inch of vertical movement. This is not problem that is keeping me from riding but this problem is just annoying me because of the jiggle the clutch lever what is fully pull in. I suspect that the black metal part the lever goes into was bent a little bit. I am wondering how I can bend this part back into the correct shape. Or if I cannot bend this part back into shape what is the part number and directions for replacing it.

Any suggestions that anyone might have would be highly appreciated.

Also I am looking for a good mechanics set of tools for under $300. Any suggestions that people have would be appreciated.




Thanks,
Nols

[BluBallz]

its easy to replace, just dismantle it from the clip on (two bolts) and take the the cable off put new stuff on bolt back on, really easy, you can get it off ebay i bet, or you can go to ANY dealer and get the part number... as for bending it back , my experience with trying to bend something back is that it just snaps right off... so if it gets you around, dont play with it:) as for the friction zone, i'd try PMing burst, he's our resident handy monkey... he may have a few answers for you. maybe as easy as adjusting your clutch cable... n e way, give him a ring...

[nols]

Thanks for the help. I'm off to the dealer to drop some cash and fix it, now only to get a nice tool set.

[Mapuda]

Personally I go with craftsman. They have sales now and then where you can pick stuff up cheap and if it breaks you take it back and they replace it no questions asked.

I have MAC and Snap-on in my box too but when that stuff breaks I have to go hunt down a tool truck and then they try and weasel out because I didn't buy it off them. Them meaning the Tool Truck driver I am trying to return it to.

As far as bending goes you can try to bend it back but it is aluminum and likes to break as Bluballz stated. You could put a fiber washer in between the lever and the perch to take up the slack.

Ask GE if he is parting out his bike.

Mike

[nd4spd]

I know what to do. Just can't figure out what tools would fit. The bolt turns with a 10mm wrench, but I don't know how to loosen the nut at the bottom. I've tried all sizes of wrench(10mmthru to 6mm) and nothing seems to fit and the location is such that it's really hard to fit the wrench head through the tiny gap. Any suggestions?

[TFK_in_Mass]

Use a pair of pliers. That's what I do. :confused:

[nd4spd]

Thanks TFK. Found a set of pliers small enough to fit through gap. New clutch lever successfully installed.

[Dom]

any other suggestions? I'm thinking maybe of getting one for the clutch but those other ones only look ok and too pricey

[PBx]

Originally posted by Cooker
Anybody have a recommendation for an aftermarket adjustable clutch lever?

Hi,

I've fitted an adjustable from a GPz500 It fits real easy and works a treat.

The details and fitting instructions are in the forums at forums.sv650.org (http://forums.sv650.org)

The site is down at the moment or I'd give a better link:(

[weegaz22]

Originally posted by Cooker
Anybody have a recommendation for an aftermarket adjustable clutch lever?

Any good or bad experience? stories?

I searched on the web, but most finds were for racing or dirt, and I'd like to avoid the imperfect match installation; I'd rather not do a "cut to size, hammer to fit" :eek: mod.

--I've heard that Lockfart-Phillips parts never quite fit. Anybody buy and install one of those?

kawasaki er500 clutch levers are supposed to fit, but you also need the assembly that bolts onto the clip-on

[PBx]

weegaz22
kawasaki er500 clutch levers are supposed to fit
Thanks for reminding me weegaz. The GPz500 and ER5 units are the same but the GPz has a black lever and the ER5 has an aluminium finish. Both come as a full assembly from the dealer, you remove the entire existing lever assy and replace it with the new one (not forgetting to short the clutch sensor wires).

[Iyindo]

Anyone know of any aftermarket adjustable clutch levers that would work on an '03 SVs?

I'm battling tendinitis and/or carpel tunnel, and my clutch lever is painful as hell... any suggestions would be most appreciated. Thanks!

[poopoohead]

try some adjustments on the clutch lever, mine is set to be very touchy up top, others set there catch point low and ive felt a clutch lever set low, it feels alot softer than mine.

im not sure but i think ive heard of some thing called roll-a-click levers. anyone else?

[stingray]

roll a click levers
http://www.constructorsrg.com/page4.html

[slowpoke]

Originally posted by Iyindo
Anyone know of any aftermarket adjustable clutch levers that would work on an '03 SVs?

I'm battling tendinitis and/or carpel tunnel, and my clutch lever is painful as hell... any suggestions would be most appreciated. Thanks!

My clutch hand would scream in pain after a couple of hours.
I noticed that when I slow down or stop, I was bracing myself with my left writst only.

I started to brace myself with my legs and torso, trying not to put any weight on my wrists.

Yesterday I was pain free!

Ice 2 or 3 times a day to get the swelling down for a couple of days until you feel better.

Don't let the pain go on for too long, because it will take an extra long time for the pain to subside once it becomes a chronic thing.

[TIE_Pilot]

I've been having twinges in my forearm on the mouse-side (right hand for me) ... I've been contemplating clipon risers or adjustable clipons...

[Knightshade]

Try out the virtual therapist on this site..you can get some advice and stretching exercises. Keep in mind, this shouldn't take the place of a visit to your doc.

http://www.sportsinjuryclinic.net/

[mojo mofo]

I was talking the same thing about pain in my left wrist (which I recently re-injured) which I shattered almost 10 years ago. I noticed that I was having issues when sitting up and using the clutch a lot. So, I went down to the local bike shop and see what my options were and my buddy Eric there said that the angle on both levers (but especailly the clutch) was too high. He grabbed a socket wrench and we turned them down so that if I am sitting up straight and extend my arms straight down over the bars they just touch the levers. I think it is gonna make a significant difference.

[Iyindo]

Thanks for all da advice guys.

:D

[Tillers_Rule]

dont bitch about your fingers hurting, thats what I do

[work4crown]

I agree with MOJO, my first ride my clutch wrist was hurting. When I got home I noticed that with elbows locked and sitting up (not laying on the tank) that in order to pull in the clutch lever my wrist had to be bent up at an awkward angle. After loosening the bolt that holds the clutch lever assembly in place I was able to rotate the assembly away from me so that the clutch lever was closer to the floor than the ceiling.

It now requires much less effort to pull the clutch lever in and my wrist isn't hurting any more.

Just make sure you don't rotate the lever so far down that it scratches your plastic bodyworks if you have an SVS.

Also, use your legs to squeeze the tank when coming to a stop and try to remember not to leave all your weight on your wrists.

I ended up doing the same thing on my brake lever and I think it is much more comfortable to ride.

[cateye36]

Has anyone has any experience with either of these two types of adjustable clutch levers? I desperately need to adjust the clutch for a small hand....

I did try to find out if this has been a prior topic, but no luck! So, I apologize if I'm repeating a thread.

Anyone? Anyone?

Thanks!

[mccoy92620]

Need help finding instructions on how to adjust the clutch engagement point -- want it to engage closer in to the bar.

Owner's manual tells how to adjust cable play......

[mccoy92620]

Oh, geez......guess it would help to say what kind of bike.....it's for
a 2003 SV650 (naked)

[DOC]

Well, if you add some play to the cable adjustment it will engage closer to the bar. Just make sure you don't go too far or it won't disengage fully.
DOC

[mccoy92620]

Thanks -- will give it a shot.......

[mccoy92620]

Thanks again, DOC -- that worked. Got the clutch to engage where I want it......but the excess play at the end is back.

There's got to be another adjustment, probably located behind the sproket cover. Any idea what size/type of tool is needed to remove the sproket cover?

[Dom]

just a socket with an extension but that adjustment is only for big changes, make sure you tighten the lock nut too, took off the cover once to find that the lock nut was just hanging free on the cable and pretty close to the sprocket.

[DOC]

Originally posted by mccoy92620
Thanks again, DOC -- that worked. Got the clutch to engage where I want it......but the excess play at the end is back.

There's got to be another adjustment, probably located behind the sproket cover. Any idea what size/type of tool is needed to remove the sproket cover? Clutch levers on these bikes are not really adjustable like the brake lever is. You might have to live with a little free play in order to make it do what you want.
DOC

[curley]

Try a Kawasaki 600 lever ( P/N 46076-1165...about $40 on Bike Bandit, ($35 on Ron Ayers)- it includes the perch and the switch I think - I have NOT tried it but I remember a reference to a ZX clutch lever on the SVrider web site - you may want to check the SVrider site and search their database - good luck!

[DOC]

Originally posted by curley
Try a Kawasaki 600 lever ( P/N 46076-1165...about $40 on Bike Bandit, ($35 on Ron Ayers)- it includes the perch and the switch I think - I have NOT tried it but I remember a reference to a ZX clutch lever on the SVrider web site - you may want to check the SVrider site and search their database - good luck! Good tip!
DOC

[druiid]

Does anyone know if there's a way to change the tension on the clutch lever so that less force would be required to pull in the clutch? I think my really tight clutch is causing some problems with my left hand joints. It takes quite a bit of force to pull it in compared to the other bikes I've been on.

[jasinner]

I'm not sure with the process for loosening the clutch on the 650 but you may want to try lubing the clutch cable also. My hand became unbearably painful and I didn't know why. I had a family member try to pull in my clutch...and they could barely move it! You can get some moly lube or graphite lube and funnel it down the tube.

[Kurt'sSV]

Yes, under the rubber flap there is the clutch lever adjustment. It screws in and out of the clutch lever. Screwing it in will give the clutch lever more play, but should make it easier to pull in if it is too tight. Just mess with it a little. Hopefully that will help.

And lube is always good for everything. :D

[druiid]

it's already screwed in almost all the way... I can try lube but it doesn't feel like it's binding. If the lube doesn't work... any other ideas?

[Kurt'sSV]

Get a new clutch cable.

[nonplus]

do the clutch adjustment under the sprocket cover. i found that in the service manual. change the position of the cable so that it doesn't stretch the spring so far. then it'll be easier to pull in.

Originally posted by druiid
it's already screwed in almost all the way... I can try lube but it doesn't feel like it's binding. If the lube doesn't work... any other ideas?

[DOC]

There is a device you can add to your clutch lever that will give a lighter pull. I saw it advertised in the back of a magazine. I believe Iyindo has one, ask her about it.
DOC

[racinteach]

it is called an "easy pull" by MOOSE...an off road product for some dirt bikes....works on street bikes to check your local shop..

[drewster]

anyone know why the brake lever on the sv/svs has a dial adjustment (1-5) but the clutch lever does not. also can you buy a clutch lever with the same adjustment.
thanks for any info.

[Tillers_Rule]

The stock one is not adjustable, THIS (http://www.buymoto.com/index.asp?PageAction=VIEWPROD&ProdID=1795) one is however.

A bit pricey, but they are very high quality, and adjustable:)

[drewster]

thanks for the info...they are pricey cause that price is US and by the time it got up here it would be well over 200$ i think...but xmas is coming maybe santa can bring hehe
nice avatar!! :D :D :D

[hornet]

will the sv1000s work mine has them and it came that way maybe a used one would be cheap