Topic: cb400f - reducing clutch lever pull effort

[lohebohi]

I am looking for ways to reduce the effort required to pull the clutch lever.  My girlfriend has small hands and she has to really stretch her hand to get to the lever.  This leaves her hands tired after she goes for a ride.  We have a brand new cable.

Option 1:
My bike has what appears to be a dirt bike lever.  She has a much easier time pulling the lever on my bike (shown in attached pic).  Just putting a lever similar to my lever would make a difference but I am not sure where to purchase and how to ensure proper fit.  I would swap mine over to hers but my lever is worn out and has a lot of play (actually a vibration and rattle sound that makes me want to replace mine as well).  Where can I get another one?

Option 2:
I could replace the 4 springs within the clutch with springs that have a lower spring constant (k).  The negative to this plan is that she would loose clamping force in the clutch. 

Option 3:
An adjustable clutch lever similar to those found on modern bikes (I know the Suzuki Bandit 1200 has them).  These levers seem to have the same effect as the dirt bike lever, as it just makes the starting position of the lever closer to the grip.  Does this option only work because the stock position of the clutch lever is further from the grip than it needs to be?  Why would they do this?  The only possible benefit I can see is that you would not have to adjust the clutch cable as often. 

Option 4:
I have seen products that change the lever arm located at the clutch and the cable down by the transmission/clutch area.  This would reduce the effort required to pull the cable, but you would have to pull the cable further.  To pull the cable further, catch 22...

I want the clutch lever to pull as smoothly as a modern CB-1 cb400f.  What happened between 1975 and 1990?  What did they change?  How did they do it? 

[GroovieGhoulie]

Dunno.  Pulled the clutch on my buddies CBR and I was AMAZED at how light it was.  My brother rode my 400 after riding a Honda Shadow 750 for a while and said that my clutch would give you a Charles Atlas forearm and hand.  Called it a "manly" clutch. 

What's funny is reading all the contemporary road tests when these bikes were new and seeing them talk about the "light clutch" on the 400s and all the Hondas for that matter.  Can't imagine what other bikes would feel like.

When I have my clutch adjusted, I need some "play" in the lever (shorter reach) because if I adjust it properly to be hard-up against the stop, it's an awful long reach for me.  Of course, I have average-sized hands, but short fingers.

[Bodi]

First, make sure the cable routing is correct. Then lube the cable thoroughly. This made a night/day difference for me. Installing a new cable actually reduced the effort a lot too, don't know why. But routing and lube are critical. The correct routing is shown in the Honda service manual.

[Barrett99]

Dennis Kirk probably has the lever in the dog leg style you want.  My 400 has a stiff clutch pull also.   My hand is not all that big and
it can be tiring in stop and go riding.  Plus the clutch tends to drag a bit in those situations, once good and hot.  Keeping the cable well lubed and adjusted properly helps.   Does anyone know if Barnett plates and springs would help cure the clutch drag and maybe
improve the clutch pull?

[TwoTired]

Option 1:
No offense, I hate those levers.  I always keep my index finger wrapped around the grip and operate the clutch with the three remaining fingers.  In this way no acceleration or deceleration G force on my arm or motorcycle bars affect clutch operation or lever position.  Inadvertant wheelies can't happen this way.  And, clutch operation on bumpy roads don't efect gear change action.   Your lever style pinches my finger.  

If you must use that lever type, remove the current lever and take it to a motorcycle shop where they can match your pivot style to your desired lever style.

Option 2:  Reject

Option 3:  See shop suggestion in option 1 response.  I think it is and engineering alternative to suggestion 2, below.

Option 4:  Take you GF to one of the museums that feature medieval devices.  Ask to borrow a "finger stretcher".  Then make the lever mods to the bike she'll take with her when she leaves you.

Suggestion 1:
 Route or reroute the clutch cable to eliminate sharp bends in the cable sheath.  A straight cable has virtually no resistance when under pressure.  The sharper the bend radius, the hight the friction forces.

Suggestion 2:   Change the clutch lever engagement position so the lever end is closer to the grip.  The lever provides more cable travel movement than is need to completely disengage the clutch.  Find the lever position that provides disengagement and remove that part of the lever travel with clutch cable adjustments.  This way, she can grab the lever near the bar end where there is more mechanical advantage instead of close to the lever pivot point.  After she becomes more practiced at using it this way, her forearm muscles will adapt to the demands and she will more easily be able to operate any lever clutch.

Suggestion 3:
  I haven't looked for a long time.  But, there used to be cable makers that used different inner sleeve or cable coating materials (like Teflon) that eases friction while encountering sharp cable bends.  Ask the local MC shop.

Suggestion 4:
Brand new cables still need to be lubed. I like the Molybdenum based lubes (Dri-Slide, for example with a 30 weight oil chaser) or a speedometer cable lube with graphite.  Just be certain that any liquid carrier for the graphite is compatible with the cable interior liner material.

Cheers,

[CB500_k2]

I am hand size challenged and found it hard to get an adequate grip on the brake lever of my CB 500. I also had to shim the clutch springs to avoid clutch slippage so my clutch is stiffer than stock.  I got a pair of power levers to extract the most out of my little hands.    The dogleg in the levers reduces the gap between the lever and the handlebars, allowing for a more effective grip.  I have noticed a significant improvement in the function of both controls.  Don't expect a transformation to modern bike hydraulic controls  performance,  just a more effective application of hand strength.  I bought a black set and a bit later an aluminum finished set.  I prefer the aluminum finish so I have the black set (still in the package) for anyone who is interested.

[crazypj]

Take a look at the aftermarket MX section. There used to be a number of hydraulic conversions for KTM, etc
PJ

[Chris Liston]

I think what your looking for is called a power lever.  check ebay - there are a few sellers selling them in brake/clutch sets.  I just bought a set, $10 bucks.  My newer master has one and I wanted the clutch to match..  The lever swings in alittle and is closer but it has the same pull distance as stock.  Works nice, although I have to sand the top of it becuase the lever is more squared than the brake lever.  Doing that just for physical lever feel though.

[hcritz]

Hey Lohebohi...
You from Baltimore?

[lohebohi]

I am a hon.

So clutch levers are clutch levers?  They will all fit? 

I think I use the same method where I keep my index finger on the grip for slow speed riding.

[TwoTired]

So clutch levers are clutch levers?  They will all fit? 

What gave you that idea?  I don't think so.  That's why you take one with you to match up the pivot and cable interface.

Cheers,

[lohebohi]

Actually all of the levers at the two shops I visited were in packaging.  I was not allowed to take the levers out of the packaging.  I had to hold my brand new switch up to the package and try to eyeball it (I did not think to bring calipers). 

We are going to try another shop and bring calipers.

[ratrods rule]

Dad  told me to always date women with small hands.

[lohebohi]

Does anyone know the part number or bike application for a clutch lever that fits our bikes?

Several people have said to just go in and any shop will have it.  That is not the case.  I spent all day driving around to 3 shops.  I found one where the hole will line up if I grind off some material but the lever not fit right in the slot. 

I have a question for the people who told me to just go look at a shop.  Was this something that you did 20 years ago?  They all look at me funny when I tell them it is for a mid 70s Honda.  These are places that sold hondas in the 70s.

Notice how on the picture from my bike the lever rests flush against the switch. 

[lohebohi]

This shows how the one that came on my bike is not stock, but still sits flush against the switch.

[TwoTired]

The dog leg style of clutch levers were never stock for the SOHC4.  Any fitment of one is going to be an adaptation of one intended for a newer bike.

If MC shops can't or won't help you, perhaps wrecking yards will, or at least allow you to examine their stock to find one that fits to your liking.

Best of luck!

[gaijin]

just saw these on ebay, maybe what you're looking for.

http://cgi.ebay.com/CB350-CB400-4-CB500T-CB550K-F-ALLOY-POWER-LEVERS_W0QQitemZ8069392081QQcategoryZ10460QQrdZ1QQcmdZViewItem