Clutch lever elongation...

[kawdude]

I've heard this mentioned several times but I need to ask the question.  How does one lengthen the lever for easier pulling?  Wouldn't lengthing the lever increase the lever throw???  How much do you lengthen it?

[mikesmith]

Remove the cable,turn the arm toward the sprocket side of the case and pull the arm out of the engine.Cut the arm in half where the cable attaches to in the center,weld in a 6-8mm section,reassemle.Gives it more leverage,didnt increase throw.

[kawdude]

But if you increase the length doesn't remove some of the clutch adjustability?

If the lever is longer is the cable long enough to fit?

[mikesmith]

Dont go over 8mm and you wont have a problem.As far as adjustment,I did mine a long time ago so I dont remember loosing adjustment, but I dont have a problem with adjustment from extending it and have gotten long life from my cluth.If I buy a new 500 Ill do it again.

[kawdude]

Excellent information thanks!

[Rick]

Leave the arm in place and opt for a quick adjust fly lever (about $100).  They use Honda ratio lever geometry and bearings in the pivot.  You get easy pull without messing with welding on the lever.

As a note, extending the lever will work, but with the quick adjust clutch you get easy pull with the added benefit of being able to adjust the clutch on the fly.  

Rick

[mikesmith]

I have both,more is better!