Help on clutch perch/lever to clear aftermarket handlebar controls

[keeena]

I'm making a Yamaha WR road-worthy. I installed a new handlebar control, but it interferes with the current clutch lever. It's an ASV lever on what appears to be an OEM clutch perch. The clutch lever's adjuster (threaded screw & locknut) hits the handlebar switch.

What are my options? I cannot move or grind the switch. The solution has to involve a new clutch perch or a new lever. Anyone hit this problem before? Would any clutch lever work? Is there a reason I wouldn't want to use one from a street bike?

I can get pictures if it helps.

[Pigman]

Hmmm Pics if ya got em....... and I have a 04 WR if you want a OEM pic to help


could be the ASV leaver....

[keeena]

Here's a pic. The chrome locknut for the adjuster screw hits the aftermarket light switch.

Even removing the locknut and tweaking the adjuster, the lever will still hit the switch. Its like I need the pivot to be away from the bars just another 1/2" to clear or a lever w/ different style (no adjuster). Also wondering a regular sport bike clutch would work, just don't know if the cable travel and lever ratio would work.

[Eric Baker]

Not the cheapest option, but CRG makes a couple pretty killer clutch perches that should give you plenty of clearance for that switch. Or maybe just a new lever that doesn't have the adjuster on the inside of the lever like that ASV one.

[Kurlon]

Or put the switch on the other side of the perch?

[keeena]

Moving the switch isn't an option unfortunately.

Looks like other mfr clutch levers have more clearance vs. ASV, so I'm probably gonna try that route.

I also found perch spacers by RSC...had no idea such a thing existed until i stumbled on their site. This would probably let me use the current ASV lever & perch. I might give RSC's entire clutch lever a try - they have a modified ratio which reduced pull effort. Found some WR450 folks using them with good results.