Author Topic: longer travel cable clutch levers  (Read 462 times)

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Offline kd

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longer travel cable clutch levers
« on: February 10, 2018, 11:21:32 AM »
I have been thinking about the value of using a longer travel clutch lever with my Muller clutch arm to make up for the reduced cable travel and plate separation. It works fine now but a little more travel would sure make finding that fine adjustment easier. A quick look on line finds several levers for small hands that actually reduce travel but none seem to show up that provide a longer stroke and travel. Looking at the stock lever, I can see how making the first bend off the pivot tighter would lift the lever farther off the grip at full travel. I don't want to try to bend one for fear of weakening it and having a fracture failure on the road. Has anyone ever researched these and do you have a link that I could follow up on? Has anyone bent one with success?
KD

Offline road-dawgs1

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Re: longer travel cable clutch levers
« Reply #1 on: February 10, 2018, 11:24:48 AM »
Aren’t the levers pretty much pot metal and attempting to bend would merely snap them?
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Offline rigidthumper

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Re: longer travel cable clutch levers
« Reply #2 on: February 10, 2018, 11:47:07 AM »
Smaller diameter grips might get you a few more thousandths of cable movement. Custom perch, that moved the pivot point further away would give you more.

Offline kd

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Re: longer travel cable clutch levers
« Reply #3 on: February 10, 2018, 11:58:23 AM »
Aren’t the levers pretty much pot metal and attempting to bend would merely snap them?

Yeah, cast aluminum I believe and that's my concern about even slightly bending with heat.

 
Smaller diameter grips might get you a few more thousandths of cable movement. Custom perch, that moved the pivot point further away would give you more.


I don't really nave fat grips and going smaller (if it's possible) with my normal sized hands would probably cause cramping and fatigue. That's the reason I was hoping someone made grips for this purpose. I find it hard to believe that these companies making the short reach ones haven't offered a slightly  long reach / longer stroke option. Even the ones with adjustable beyond the hinge levers only adjust for small hands which causes a shorter stroke. They provide a caution for that consequence.
KD

Offline Ohio HD

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Re: longer travel cable clutch levers
« Reply #4 on: February 10, 2018, 12:10:55 PM »
Get a spare lever assy from eBay, and work on removing material from the stop areas, where the lever fits against the bracket. That would give some more cable travel. Heck 0.010" more push rod travel is huge to the clutch. You'd have to experiment with how much to remove from the lever and bracket.

Or, cut and weld the lever. Or do both.


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Offline kd

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Re: longer travel cable clutch levers
« Reply #5 on: February 10, 2018, 12:20:28 PM »
That is starting to look like the only option. We're still talking about welding crap aluminum casting. If it has any impurities it can be tough but I suppose doable. I'd hate to have one fail in traffic or sitting at a Red light.
KD

Offline Leed

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Re: longer travel cable clutch levers
« Reply #6 on: February 10, 2018, 01:06:22 PM »
If you know a good machinist he could fab up a lever for you.
A friend of mine machined a new lever for a  co-worker who had lost parts of his fingers in an accident.   He was able to ride his Harley more comfortably with the new lever.

Offline Hossamania

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Re: longer travel cable clutch levers
« Reply #7 on: February 10, 2018, 01:49:21 PM »
When I dropped one of my old bikes, it bent the lever out a bit without breaking it. So I know it can be done...  Dirt bikes can be seen all the time with bent handles, some curled halfway around.
Maybe some heat with some gentle coaxing.
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Offline koko3052

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Re: longer travel cable clutch levers
« Reply #8 on: February 10, 2018, 02:32:15 PM »
KD, mill some out of some flat bar.

Offline FSG

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Re: longer travel cable clutch levers
« Reply #9 on: February 10, 2018, 02:37:17 PM »
some flashy levers touchdown on the grips in the purple area

a buffer pad usually takes a bit off to improve things


Offline speedzter

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Offline Ohio HD

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Re: longer travel cable clutch levers
« Reply #11 on: February 10, 2018, 03:43:29 PM »
Kirk, just one thing I wonder about, at what point does the Muller top out? The way it's designed if it tops out from excess cable travel, the ball bearings will try to ride out of the inner ramp. The HD design would just bring the clutch push rod backwards as it won't top out. It goes past the top and comes down again.

Added: Actually, let me rethink that, the HD unit won't go backwards, it just has a wider slot for the bearing, and it actually would keep going till it runs out of travel.
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Offline PIRSCH FIRE WAGON

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Re: longer travel cable clutch levers
« Reply #12 on: February 10, 2018, 04:28:02 PM »
This is what I use:
http://www.oberon-performance.co.uk/acatalog/Harley_Davidson_Cable_Clutch_Models_Adjustable_Levers-1.html




I have installed these for several customers on Both Spring and Hydraulic. All Motor Police Officers. Makes a world of difference.
Tom

Offline Ohio HD

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Re: longer travel cable clutch levers
« Reply #13 on: February 10, 2018, 04:33:50 PM »
How much further away from the grip can these be adjusted in relation to a stock lever?
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Offline kd

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Re: longer travel cable clutch levers
« Reply #14 on: February 10, 2018, 04:39:36 PM »
They’re pricey but if they work they could be just the edge needed to ensure a clean release. I’d love to have another .020 at the pressure plate.
KD

Offline Ohio HD

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Re: longer travel cable clutch levers
« Reply #15 on: February 10, 2018, 04:44:21 PM »
How much do you have now?
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Offline kd

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Re: longer travel cable clutch levers
« Reply #16 on: February 10, 2018, 05:00:30 PM »
How much further away from the grip can these be adjusted in relation to a stock lever?


The description says it is 7” long pivot to end of ball and I confirmed it matches stock.
The “total” adjustment “available is 30mm or 1 1/8”.
The center of the adjustment is said to be “close” to stock so that to me means about 9/16 “ extra clutch cable movement available. (Or 9/16 further from the grip)
What that relates to at the pressure plate is beyond my quick calc ability.  :nix:   :scratch:


How much do you have now?


If you mean me and what lever travel, it’s tough to measure on the length of the lever because it is different at any given point on the length.  If you mean plate movement, I have .050 / .052 adjusted. It works well with a the bandit in an EVO 49 tooth basket. I just feel a little more travel would make initial cold operation maybe nicer even though it’s not bad.
KD

Offline Ohio HD

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Re: longer travel cable clutch levers
« Reply #17 on: February 10, 2018, 05:07:26 PM »
How much do you have now?


If you mean me and what lever travel, it’s tough to measure on the length of the lever because it is different at any given point on the length.  If you mean plate movement, I have .050 / .052 adjusted. It works well with a the bandit in an EVO 49 tooth basket. I just feel a little more travel would make initial cold operation maybe nicer even though it’s not bad.

I agree, more would be helpful. At 0.055" ish, neutral was at times tricky, especially due to the heavy lever pressure required now. I have about 0.024" more going to the 21° ramps and a new cable. After I have the Mullers in, I may end up taking them back out if 0.055" is all I can get.
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Offline Ohio HD

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Re: longer travel cable clutch levers
« Reply #18 on: February 10, 2018, 05:09:19 PM »
How much further away from the grip can these be adjusted in relation to a stock lever?


The description says it is 7” long pivot to end of ball and I confirmed it matches stock.
The “total” adjustment “available is 30mm or 1 1/8”.
The center of the adjustment is said to be “close” to stock so that to me means about 9/16 “ extra clutch cable movement available. (Or 9/16 further from the grip)
What that relates to at the pressure plate is beyond my quick calc ability.  :nix:   :scratch:

I was hoping that one of the guys that put them on had a measure from the grip, in relation to what an OEM lever measure on the same bike.
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Offline kd

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Re: longer travel cable clutch levers
« Reply #19 on: February 10, 2018, 05:16:32 PM »
That’s a tough measurement to get. It’s very subjective and depends on how far down the clutch handle you take that measurement. I suppose you could agree on a point like at the ball tip contact to the grip or 3 1/2 “ from the ball tip or pivot (which is half way).
KD

Offline Ohio HD

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Re: longer travel cable clutch levers
« Reply #20 on: February 10, 2018, 05:20:59 PM »
Well, then the measure can be how far away from the bracket does the lever travel now.

Things like measuring the lever distance from the grip, I would use a gauge I'll make that sets the distance from say the end of the handlebar, then use a feeler gauge to get the same spot away from the shim to the lever. It can be done. 
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Offline kd

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Re: longer travel cable clutch levers
« Reply #21 on: February 10, 2018, 06:25:19 PM »
I have my primary off right now and a dial indicator set up for measurement. I can’t get on it tonight but I’ll try to do it as early as I can tomorrow. I’ll l measure how much plate travel corresponds with 9/16 lever movement at the ball. That will be worse case scenario. I’ll try to email them and find out where they measure the 1 1/8” they state in their notes. Either way, if 9/16 at the ball end gives significant movement at the pressure plate (to give stock or suitable plate separation of .070 or more) then where they measure from is irrelevant.
KD

Offline speedzter

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Re: longer travel cable clutch levers
« Reply #22 on: February 10, 2018, 08:52:42 PM »
I've taken a few pic's, and I'll link them soon.
I have a a Barnett extra plate clutch with a BDL ball bearing locker.
I managed to get a bit over .063 travel with the late 18 degree ramps

https://photos.app.goo.gl/p846c686k9tCrEjo1
« Last Edit: February 10, 2018, 09:01:59 PM by speedzter »

Offline Ohio HD

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Re: longer travel cable clutch levers
« Reply #23 on: February 10, 2018, 08:59:03 PM »
Thanks, like to see them.
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Offline FSG

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Re: longer travel cable clutch levers
« Reply #24 on: February 10, 2018, 09:49:43 PM »
these are speedzter pix









« Last Edit: February 11, 2018, 01:07:40 AM by FSG »