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Old October 17th, 2021, 02:13 PM   #1
jjmaine
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My DIY “Adjustable” clutch lever

Many that own a 300 feel that the clutch lever is too far away from the grip especially since it takes hardly any movement to activate the clutch.

I had installed short CRG levers but I actually prefer the feel of the oem levers believe it or not. Some just back off the clutch adjuster which allows you to get the lever closer to the grip but it creates a lot of slop in the lever which I did not like. I decided to drill and tap the lever to take a 4-40 stainless steel set screw which I can adjust to move the lever closer to the grip.

There is plenty of room in the stock clutch cable and doing this does not interfere with the clutch safety switch that I can tell. I tested it before and after and it works the same.

If you wanted to do this but dont want to tap it for threads you could just drill a hole and epoxy/glue in a piece of rod longer than you need and then just keep grinding it off and test fitting until the lever sits where you like it. It does not need to be that strong as it just acts as a stop and keeps the lever from flopping in the wind lol. I sanded down the bump on the lever but it was not necessary. Also drilled and tapped for two screws but one on the top worked just fine. Not bad for $0.52😃
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Old October 17th, 2021, 07:50 PM   #2
BonelessSugar
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Nice idea, cheaper to customize the ones you have than to replace them.
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Old October 18th, 2021, 11:28 AM   #3
DannoXYZ
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Quote:
Originally Posted by jjmaine View Post
Many that own a 300 feel that the clutch lever is too far away from the grip especially since it takes hardly any movement to activate the clutch.
Cable too tight?

Good job on adding adjust-ability to lever!
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Old October 18th, 2021, 12:11 PM   #4
jjmaine
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Thanks Boneless and Danny. No the cable isn't too tight it is just that the lever is very far from the grip in the stock position. I hated it and I have what I would call average sized man hands lol. I have had 2 Ninja 250's, a Ninja 500 and a ZZR 600 before this 300 and this is the only clutch that I didn't like as it came. I'm not a fan of the overall "feel" of the clutch action either but am getting used to it. I think it may have something to do with it being a slipper clutch?

I can't put my finger on it exactly but it just feels a bit off to me as using a clutch and shifting has never been an issue for me (except my first summer riding) but with this bike I find myself having to concentrate with my shifts or it gets clunky.
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Old October 18th, 2021, 03:04 PM   #5
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Could be slipper-clutch, although its action doesn't come into play until you're engine-braking.

Do you have cable well-lubed? With both ends disconnected, drip oil into upper end while you floss cable full-stroke. Keep on dripping oil in until it drips out bottom end.

Common complaint on 400 is clutch feel is too light. There's replacement spring available for it that makes for more firm lever feel. Perhaps something like that can be done on 300.
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Old October 19th, 2021, 03:52 AM   #6
jjmaine
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Quote:
Originally Posted by DannoXYZ View Post
Could be slipper-clutch, although its action doesn't come into play until you're engine-braking.

Do you have cable well-lubed? With both ends disconnected, drip oil into upper end while you floss cable full-stroke. Keep on dripping oil in until it drips out bottom end.

Common complaint on 400 is clutch feel is too light. There's replacement spring available for it that makes for more firm lever feel. Perhaps something like that can be done on 300.
Actually maybe it isnt the slipper part that makes it feel weird to me but it has some type of “assist” to make the lever easier to pull (I forget what they call it but I can check in the service manual). Different from the previous 250’s the way i understand it. Cable is all lubed and working correctly, Im just not a fan of the way it feels but thats just how it is haha. It really is not bad at all, all of the engagement is at the end of the lever so it doesn’t feel as progressive as most clutches? Not sure if that makes sense? Thanks for the suggestions though!

Thinking about it, it closer resembles my dirtbike clutch after I removed the judder spring and replaced it with a regular fiber disk so it would grab better and have a more direct clutch engagement….
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Old October 19th, 2021, 11:12 AM   #7
DannoXYZ
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Quote:
Originally Posted by jjmaine View Post
It really is not bad at all, all of the engagement is at the end of the lever so it doesn’t feel as progressive as most clutches?
By "end of the lever", do you mean engagement/disengagement point is close to end when you release lever? Or when you start to release lever? Try to adjust so engagement is closer to middle:

end of release = loosen cable
start of release = tighten cable

Here's some mods to 400 slipper-clutch, perhaps something similar can be done to 300?
https://www.norton-motorsports.com/k...ned-and-fixed/
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Old October 23rd, 2021, 06:40 AM   #8
jjmaine
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Quote:
Originally Posted by DannoXYZ View Post
By "end of the lever", do you mean engagement/disengagement point is close to end when you release lever? Or when you start to release lever? Try to adjust so engagement is closer to middle:

end of release = loosen cable
start of release = tighten cable

Here's some mods to 400 slipper-clutch, perhaps something similar can be done to 300?
https://www.norton-motorsports.com/k...ned-and-fixed/
Yes, close to the end as in loosening the cable. That was the reason for adding a set screw to my lever, to take up all the excess freeplay the lever has after loosening the cable.
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