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Old 05-06-2005, 10:01 PM   #1 (permalink)
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I wanted to install CRG Roll-A-Click Adjustable levers but the application isn't available for the Speed Triple. I even checked directly with CRG, but no joy.





Actually not 100% true - the brake lever is the same as most common models of Suzuki/Kawasaki/Yamaha but there's nothing for the clutch side.
So the challenge was to find a way to accomodate an alternate clutch lever.



Here's what we're starting with:





So a little improvisation had to be brought to bear: I did a little sleuthing & looked for a clutch perch that would be somewhat compatible from another bike manufacturer.



I found the late model Kawasaki's had a very similar bracket and ordered the ZX12 model clutch perch complete assembly (including lever) - Kawasaki part # 46076-0015 - $50 + local tax.





Now you need the bracket clamp from the Triumph in order to retain your OEM mirror, as the clamp has the mirror mount.
(If you are using bar-end mirrors, you can skip this step & just use the complete Kawa perch/bracket assembly)





The bracket clamps are almost the same but the holes are just a little wider apart on the Triumph clamp - so you need to elongate the holes to make the Triumph OEM bracket fit the Kawa perch assembly - that just took about 2 mins with a rat-tail file.
Tip - do the bottom hole first and file until the "lip" fits snugly over the top part of the bracket (this will make sense when you do it); then follow up with the top hole.
You can see from the pic immediately below that it doesn't need much - only a few mm.





Here now is the lever/perch assembly with the Triumph bracket fitted ready to mount on the bike.





So then, it's just a case of re-installing the clutch actuator cable into the new perch assembly, fit on the bar using the modified Triumph bracket and re-install the mirror.




The next detail is the clutch interlock switch which is different between the two systems (the new Kawa perch assembly comes complete with the switch so that part is good!). I stared at this for a while trying to figure out how best to do it - the Triumph has a switch that comes pre-connected onto a short harness with plug that is about 9" or so from the perch assembly.





I wondered where I could get the plug that fits into the Kawa switch - the difference with the Kawa is that the plug from that goes into the left bar switch assembly, so the only way to buy that would be to get the whole switch & hack it off! (They are available occasionally on E-bay so that is an option that a perfectionist might consider to keep all the Triumph parts intact)

Then it struck me in a Euraka!!!!!! moment that the interconnect plug was the same as that for the Kawa switch!!!

... But not long enough to reach the perch by a long way. So I pared back the harness & cut the plug off with the plan to extend it.





There are actually three wires in that small mini section of harness that went to the intermediate connector plug for the clutch switch: only the outside two pins of the 3 are used so you can ignore the black/red wire - just trim this off; you need to extend the remaining two, the black & black/yellow wires, to the plug.







Be sure to solder and use a heat-shrink rubber sleeve.
(Note: save the weather shield - you can slide this over the switch once it's connected)


Repeat the solder/heat-shrink insulation process at the open harness end





(Note the black/red is un-terminated - also, it is not important to be super critical to ensure you get the correct extension wire to the same original i.e. if the black ends up going to the black/yellow & vice/versa it doesn't matter - note that I used two black wires for extension & didn't even check which was which - this is OK!!)



Now, just wrap it up with black electrical tape to seal the harness where you had to open it, plug in the clutch switch plug & you're done!












So the prep is all done - now I'm just waiting on my CRG's to come in, then it's just simply swap out the levers.


The CRG part #'s you need are AN-521 for the brake lever (no mod necessary on the brake side) and the AN-681 for the clutch lever.
These are the regular lever part #’s – you have additional options in colour or standard or shorty length; they also have folding versions - check the CRG website link above for the different choices you have.


I'll update with new final pics when I get my new levers installed, which should be middle of the week.
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Old 05-06-2005, 10:24 PM   #2 (permalink)
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That's a great mod for the CRG levers and you did a nice job!l. I went with the DPR dogleg levers fron Jack Lilley. If I had seen your mod a year ago, I would have followed your tips, because the DRG's are way cool! Good job!
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Old 05-06-2005, 10:42 PM   #3 (permalink)
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Nice mod.

i just mounted an '05 Triumph adjustable clutch lever/perch assembly on my '03. It was a straight bolt-on and moves the lever closer to the handlebar.

The only downside i can see is that the offset distance from lever pivot-bolt to cable end has increased by approximately 1/4". Doesn't seem like a lot but it definitely increases the lever effort.



[ This message was edited by: geezerx on 2005-05-06 21:38 ]
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Old 05-07-2005, 04:36 AM   #4 (permalink)
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DEcosse,

Awesome post! Thanks for the detailed instructions and photos.
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Old 05-07-2005, 09:30 AM   #5 (permalink)
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DEcosse, got a favor to ask of ya. When the Kawi lever comes off could you send to me or post a pic of it posed similarly to the levers pictured in my above post?

And could you also include a couple of measurements?

- distance from center of lever pivot-bolt hole to center of cable-end hole.
- diameter of lever pivot-bolt hole.
- Thickness of lever as measured through the lever pivot-bolt hole from top to bottom.

ok, that's three. yup, a couple. :upthumb:

I need to make a change at one end of the clutch cable or the other to reduce that lever effort.

:chug: :chug: :chug:

[ This message was edited by: geezerx on 2005-05-07 07:32 ]
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Old 05-07-2005, 06:35 PM   #6 (permalink)
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Geezerx, the Triumph OEM measures at 29mm (centre/centre) by my eye - no caliper; as best as I can tell on the bike, the Kawa lever looks pretty close to that.
When I switch out for the CRG, I'll post a similar pic to yours with all 3 and get a more accurate read on the dimensions.
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Old 05-08-2005, 12:49 AM   #7 (permalink)
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DEcosse, thank you. :yayyy:





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Old 05-08-2005, 12:13 PM   #8 (permalink)
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Check this out Geezerx -

clutch actuator mod

Here's another pic of the mod by someone else



There appears to be some suggestion the '05 actuator arm is longer - maybe someone with an '05 can post a close-up pic and and a measurement?
(centre/centre measurement on the stock arm seems to be ~30mm)

When I researching the clutch lever options at my local dealer I found the clutch effort on the Kawasakis is a fraction of that of the Triumph - my brother-in-law just picked up a Kawasaki & brought it by yesterday & we compared side-side - what an incredible difference!

I am definitely going to do the extension mod one way or other - either '05 arm or the DIY extension if it ends up being the same

[ This message was edited by: DEcosse on 2005-05-08 11:01 ]
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Old 05-08-2005, 01:25 PM   #9 (permalink)
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DEcosse, that's one of the options I have on the back burner. An '04SE Daytona, the '05 Speed Triple and the '05 Sprint are bikes of which I am aware that have the longer actuator arms.

If I stay with this lever/perch combination, a quick cobble or arm replacement at the other end will likely be the next step.

It's give and take in the long run. The way it is now gives me a harder but shorter pull length to full disengage. The longer arm will ease but lengthen the pull. The shorter pull length allows me to adjust the lever closer to the handlebar which is a plus for me.

My head hurts.

The actuator arm on my '03 is ~30mm also. Dagnabit, I was just at a Triumph dealer yesterday. Never thought to actually measure the arms I was looking at. : ">



[ This message was edited by: geezerx on 2005-05-08 12:26 ]
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Old 05-19-2005, 01:07 AM   #10 (permalink)
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Find CRG Roll-A-Click Lever Mod Part-2 here.

There was a question from another thread that I'd like to incorporate here also - if you have any other kind of after-market levers that aren't available for the Triumph, you can also use the Kawi perch for that purpose too
e.g. Carbon Fibre

[ This message was edited by: DEcosse on 2005-05-19 19:03 ]
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Last edited by DEcosse; 09-12-2007 at 08:35 PM.
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