Shorty Lever Clutch side problem

[xxjarrodxx]

Trying to install the shorty lever on a Ninja 250 clutch side. The brake side went on really easy but when I try to put on the clutch side it seems to be in a bind and won't allow me to get it set right. Is it normal to have to adjust the clutch cable when installing these? Thanks

[rojoracing53]

Originally Posted by xxjarrodxx

Trying to install the shorty lever on a Ninja 250 clutch side. The brake side went on really easy but when I try to put on the clutch side it seems to be in a bind and won't allow me to get it set right. Is it normal to have to adjust the clutch cable when installing these? Thanks

Yes it is normal to adjust it. I always loosen everything up and and readjust from scratch when going with a new lever design.

[xxjarrodxx]

Is there an easy way to do this that I overlooked?

[rojoracing53]

Loosen the slack up top and down on the clutch cover if this still isn't enough your lever may not be right. Are you just replace the lever or the whole perch as well. I just tried to install one of my CRG superbike clutch lever & perch assembly but it's going to require an extra 1/2 inch of free cable to fit.

Pics of your stock and new lever to compare would help.

[xxjarrodxx]

I'll take some when i get home, i am out of town right now. But it is the perch and lever.

[rojoracing53]

Ok so here is what I was talking about. I don't have the stock lever handy and th pictures kind of suck but I hope you'll understand what messurment I'm talking about from this. First is the stock clutch perch with 27mm of exposed cable from the ball end to the housing ferrule.



Next is my CRG clutch lever and perch assembly with 38mm of necessary exposed cable needed.



Now 11mm doesn't sound like a whole lot of difference but I was just enough to make fitting the new setup impossible with the stock cable. I'm going to try and find a cable with a slightly longer inner cable and give it another go.

[xxjarrodxx]

That makes perfect sense, what brand levers are those? I was hoping I would have enough slack in my cable to do it with the stock one but I guess that might not be possible.

[rojoracing53]

I don't remember the model # or anything since they used to sponsor me and just gave us what we needed. The Brand is CRG and the quality is what you would expect from a $250-300 lever I have on a pair of the2wheel adjustable levers and for $50 for the SET they good but after a year and 20,000 miles the color is faded and the play in the joints is getting pretty bad. The 6061 aluminum alloy the Chinese parts houses claim to make they parts out of is not really up to 6061 spec and it will bend, warp and wear much faster then the quality parts for 4-5 times the price.

[xxjarrodxx]

The ones I bought are PSR, they are pretty cheap but seem to be decent quality.

[rojoracing53]

I don't see any PSR perches available so ether I can't find them or you misunderstood my earlier question. These PSR levers look like exact knock offs of the CRG & Pazzo stuff so If you are just installing the lever then it should work if they didn't send you the wrong one. If you truly do have the clutch perch like the one I posted a Picture of then get a picture with a mm scale like I did and we can go from there.

[VanGhost]

Hello. I saw this post and figured I would plead for help. I just installed Pazzo Ebay replica shorts on both. Now my clutch is not working. I can go into first without clutching. When I squeeze lever bike is very difficult to free wheel. Works great in neutral. I cannot go up from there. I am new to working on a mc, but wanot to learn and do what I can myself. With being destitute and penniless, it helps.
Would anyone please be so kind to give me some advice? I was told to play with adjuster by lever, no good. Someone else said that I need to adjust cable on right as well, due to short levers not having the full stroke as the stock. ???

[snot]

You may need to adjust both ends. You should have a little free play in the lever (i think it's 1-2mm). It is possible you will need a longer cable depending on the brand.

[JohnnyBravo]

If you run out of adjustment by the lever go see if you can adjust the other end

[VanGhost]

It does pull the clutch arm..I think is term...on right side, just not engaging clutch. That is what threw me off

[JohnnyBravo]

Originally Posted by VanGhost

It does pull the clutch arm..I think is term...on right side, just not engaging clutch. That is what threw me off

Like moving a gear shifter around without putting something in gear... You can move stuff all you want, but if you don't move it the right amount you just making the motions