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Old 05-01-2007, 08:25 PM   #1
boyscout OP
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Aftermarket clutch perch for lc4 Adventure?

I've got a 2002 ktm adventure that is on it's third clutch cable in 12K miles. Sure, they are easy to replace and I now ride with two cables zip tied next to each other but I find the poor design of the KTM clutch perch annoying and am considering replacing it. I don't want to go hydraulic and am wondering what aftermarket clutch perches people have tried. Looks like a Works Connection or ASV might add a bit of bling along with functionality.

Anybody using one of them?
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Old 05-01-2007, 08:53 PM   #2
Donkey Hotey
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Man, where is the cable failing? All of my LC4s have the original clutch cables on them. I'm assuming you have the stock Domino perch (with the concentrically located compression release)?

Are you greasing the barell where it goes into the lever? It wants to pivot there, not bend. If it's dry, it will bend the cable over and over at that point, eventually causing a failure.
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Old 05-01-2007, 10:13 PM   #3
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Quote:
Originally Posted by Donkey Hotey
Man, where is the cable failing?
I should post a picture. I caught this one before it actually broke. I saw a single strand poking loose right at the top of the housing. Took the cable off and slid the housing back to find it totally shredded inside.

Quote:
Are you greasing the barell where it goes into the lever?
It broke farther down the cable than that. To be honest I don't really pay a lot of attention to my cables. I guess it's that I've put a lot more miles than this on other bikes and never had problems with cables breaking.
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Old 05-01-2007, 10:34 PM   #4
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I wonder if they changed suppliers. Mine are: 1996, 1997 and 1999.

That is odd. I've never had a cable fail inside the housing like that (on any bike). Now ya' got me worried about what to do when/if mine wear out.
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Old 05-01-2007, 11:31 PM   #5
bmwktmbill
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'02 640a, 18.5K miles.
Just changed the clutch cable. It was in perfect shape.
I oil it every 2K miles up at the perch and at the engine.
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Old 05-02-2007, 10:23 AM   #6
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Let me ask this then. How much lateral (up and down) play is there in your clutch lever? I've got a good inch to inch and a half of lateral movement in the clutch lever which just makes the clutch feel sloppy and I always figured contributed to my clutch cable issues.

Is this normal or do I have a gravity customized clutch perch?
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Old 05-02-2007, 10:29 AM   #7
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Quote:
Originally Posted by boyscout
Let me ask this then. How much lateral (up and down) play is there in your clutch lever? I've got a good inch to inch and a half of lateral movement in the clutch lever which just makes the clutch feel sloppy and I always figured contributed to my clutch cable issues.

Is this normal or do I have a gravity customized clutch perch?
Yes it has been vibrationally adjusted, pivot is worn out
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Old 05-02-2007, 01:58 PM   #8
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See the last chapter:
http://www.advrider.com/forums/showp...9&postcount=13
I think you have got the ones from the bad lot.
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Old 05-02-2007, 03:27 PM   #9
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Don't know whether I got a "Monday Morning" clutch perch or whether I just custom modified it by slamming it into things, but I think it needs to be rebuilt or replaced. I'd really like my clutch to feel precise rather than just being a blunt instrument I mash. I think it would be awesome to be able to two finger it while standing and that is nowhere near possible currently. I'm going to try shimming the pivot, but am still thinking seriously about replacing it.

So back to my original question. Has anybody out there put an aftermarket clutch perch on their Lc4 Adventure?
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Old 05-02-2007, 08:42 PM   #10
Donkey Hotey
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Well, the perch doesn't hold the lever from thrust on the sides but rather the fit of the center bushing to the lever. It sounds like the bushing and perhaps the lever have worn out. I just checked my '99 Adventure and it's sloppy as hell--just like yours.

But upon looking at it, I'm reminded of why it's hard to replace. It holds the compression release cable so you'll have to buy something that has a compatible lever. It's the mirror mount so you'll have to figure that out. It's also got your starter interlock wiring that you'll have to bypass.

With that out of the way, the first choice would be the ASV folding levers. I'd guess you could call them and tell them your desires. At best I think that would get you a clutch and compression release but you'd have to solve the mirror mount and interlock switch. You might be able to use their hotstart lever for your compression release.

http://asvinventions.com/



An added bonus is they sell a matching lever for the Magura master cylinder so you could match it on the other side.

Has anybody tried to fit the ASV perch to an LC4 that can lend an opinion?
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Old 05-02-2007, 08:50 PM   #11
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Quote:
Originally Posted by Donkey Hotey
Well, the perch doesn't hold the lever from thrust on the sides but rather the fit of the center bushing to the lever. It sounds like the bushing and perhaps the lever have worn out. I just checked my '99 Adventure and it's sloppy as hell--just like yours.

But upon looking at it, I'm reminded of why it's hard to replace. It holds the compression release cable so you'll have to buy something that has a compatible lever. It's the mirror mount so you'll have to figure that out. It's also got your starter interlock wiring that you'll have to bypass.

With that out of the way, the first choice would be the ASV folding levers. I'd guess you could call them and tell them your desires. At best I think that would get you a clutch and compression release but you'd have to solve the mirror mount and interlock switch. You might be able to use their hotstart lever for your compression release.

http://asvinventions.com/



An added bonus is they sell a matching lever for the Magura master cylinder so you could match it on the other side.

Has anybody tried to fit the ASV perch to an LC4 that can lend an opinion?
ASV levers are not a direct bolt on replacement for a 640 Adventure. The brake lever does not have the little lip on it to turn off the brake light switch. And the clutch lever does not have a groove on the push rod to work with the brembo dust cover. I ordered some and ended up sending them back and going with the stock brembo levers.
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Old 05-03-2007, 12:59 PM   #12
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That's pretty much what I was thinking. I don't really care about the clutch interlock and I can figure out another mirror mount. It's the hotstart to compression release that I don't know about. I'm also not so sure about the hot start getting in the way of the the switch assemby. Think I'll send them an email.

Of course the other downside is it better well be the last brake lever I buy. If I do break it, I'm sure going to have a hard time finding spare parts other than through them.

Quote:
Originally Posted by Donkey Hotey
Well, the perch doesn't hold the lever from thrust on the sides but rather the fit of the center bushing to the lever. It sounds like the bushing and perhaps the lever have worn out. I just checked my '99 Adventure and it's sloppy as hell--just like yours.

But upon looking at it, I'm reminded of why it's hard to replace. It holds the compression release cable so you'll have to buy something that has a compatible lever. It's the mirror mount so you'll have to figure that out. It's also got your starter interlock wiring that you'll have to bypass.

With that out of the way, the first choice would be the ASV folding levers. I'd guess you could call them and tell them your desires. At best I think that would get you a clutch and compression release but you'd have to solve the mirror mount and interlock switch. You might be able to use their hotstart lever for your compression release.

http://asvinventions.com/

An added bonus is they sell a matching lever for the Magura master cylinder so you could match it on the other side.

Has anybody tried to fit the ASV perch to an LC4 that can lend an opinion?
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Old 05-03-2007, 01:02 PM   #13
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hmmm. Looks like the Pro version clutch lever comes with it's own dust cover. The brake light problem may be more difficult.

Quote:
Originally Posted by Odysseus
ASV levers are not a direct bolt on replacement for a 640 Adventure. The brake lever does not have the little lip on it to turn off the brake light switch. And the clutch lever does not have a groove on the push rod to work with the brembo dust cover. I ordered some and ended up sending them back and going with the stock brembo levers.
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Old 05-04-2007, 07:03 PM   #14
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Well I guess I was destined to get a new clutch perch. Look what I did on my way to work today.


And here's a picture of the previously shredded clutch cable that I've decided was likely due to a combination of lack of cable maintenance and a worn out pivot.


On the shopping list

1. New clutch perch and lever
2. Better bash guards
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Old 03-23-2008, 11:19 AM   #15
666
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So, Does anybody know about adjustbale clutch lever for on pre 2003 adv?
I have hard time reaching clutch when it gets technical. My fingers are too short.
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