Suzuki 800 Intruder Club & Forum
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Suzuki 800 Intruder Club & Forum

A UK Site Dedicated To The Suzuki C800, VL800, VX800, M800, VZ800, VS800, C50, M50 Model Intruder / Boulevard / Marauder
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PostSubject: CLUTCH LEVER SPAN REDUCTION MOD   Wed Sep 10, 2014 11:29 am

Having the same problem as a few others in that the clutch lever is too far from the bar with no adjustment to make operation comfortable I have come up with a simple mod for our bikes.

On the clutch lever there is a metal tab on the underside which operates the clutch interlock switch. What I have decided to do is to drill a small hole in the tab and insert a machine screw with a nut either end to secure. In hindsight it would probably be better to tap this hole for easier adjustment. The screw can then be used to move the clutch lever nearer the bar. 
You need to loosen the clutch cable off then readjust when you find a comfortable lever span. I moved mine 1/4 " and it is now so much easier to operate. 
The clutch friction zone only takes up a small amount of the lever movement so I have had no problems with slippage or gear shifting. 
I may not have explained this very well but have attached a few images which may help

This shows the adjustment screw from the top

This shows the underside with the adjustment screw sitting above the plunger to operate the clutch switch.

This show the amount of adjustment I made. 

This is a quick and simple mod which I have found works perfectly well
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PostSubject: Re: CLUTCH LEVER SPAN REDUCTION MOD   Wed Sep 10, 2014 11:32 am

Sorry underside photo attached. 

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PostSubject: Re: CLUTCH LEVER SPAN REDUCTION MOD   Wed Sep 10, 2014 11:49 am

Hey Ricky,

Sound idea ! ... I fully understand what you have done & why. nicely illustrated with helpful photos. I agree with your comment re-possibly better to tap a thread in the tab, but it would be best to keep a lock nut on the machine screw you made your adjuster from.

You've covered the angle of clutch actuation range so all should be well.   lgd

In the olden days people use to go to dog leg levers to achieve the same ends !

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captain crash
Mentally Deficient lunatic ..... & ..... Site Moderator

PostSubject: Re: CLUTCH LEVER SPAN REDUCTION MOD   Wed Sep 10, 2014 4:55 pm

Nice one Ricky 
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.. Mechanical Tart .. .. Site Moderator ..

PostSubject: Re: CLUTCH LEVER SPAN REDUCTION MOD   Wed Sep 10, 2014 6:17 pm

Good thinking Ricky, good 1  
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PostSubject: Re: CLUTCH LEVER SPAN REDUCTION MOD   Mon Nov 10, 2014 5:27 pm

quicker solution is to fit a rubber grommet over the cable between the lever & the mount to act as a buffer
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