Japanese handlebar switches and clutch lever

i am contemplating doing a conversion to use a set of UJM brake MC/Clutch/switchs. from what ive seen the japanese style clutch lever uses a smaller dia and width ferrel aon the lever end. has anyone done such a mod?

The Magura clutch perch and lever that CNW sells needs a ferrule that is slightly smaller than the standared commando one.

I simply drilled the hole out a bit slightly and filed down the top of the barrel and now it works fine .

Did the same as Gort with the CNW parts. You can also remove the cable end piece (whatever it's called) and solder a new one of the correct size in place. I've done that many times with various clutch/brake levers/cables (But watch for stainless steel cables - you'll need specific flux)!

MexicoMike said:

Did the same as Gort with the CNW parts. You can also remove the cable end piece (whatever it's called) and solder a new one of the correct size in place. I've done that many times with various clutch/brake levers/cables (But watch for stainless steel cables - you'll need specific flux)!

Click to expand...

...and a safety caveat for all (particularly brake cables!!!) - make sure you "birds nest" the wires (ie: spread out) before soldering.
This ensures the nipple (whatever it's called in your land) can't pull off with potentially disastrous consequences.

Thanks Robs, I should have mentioned that! The solder is there to keep the "birds nest" spread out so the cable takes the load, not the solder!

Tommaselli levers as were used on older Ducatis look better on old British bikes. They resemble Doherty levers in some ways. Most Japanese rubbish stands out like dog's balls, as being non-genuine. I use a Lockheed racing master cylinder which looks right with the Tommaselli clutch lever.

Tommaselli :

https://www.lowbrowcustoms.com/tommaselli-style-alloy-control-brake-clutch-levers.html


Doherty :

https://www.google.com.au/search?q=...iAhXs6nMBHfJpCMIQsAR6BAgJEAE&biw=1920&bih=906

The Magura levers look pretty good (better than the Tommaselli IMHO) and a very close match to Brembo levers.

I agree with the above. I used Yamaha levers from Mikes XS, same issue, just drill out the ferrule hole, make sure it rotates smoothly. I had to file the slot a little to make the Norton adjuster work.

Also just be aware that it is critcal to use a lever with the same fulcrum distance as what the std lever has ie the measurement from the center of the pivot bolt to the center of the cable nipple.Tommaselli for example has 2 different dog type levers that can be purchased,one is about 23mm and the other is 31mm .I bought the smaller one and found it fitted well,gave nice light pull on the lever but would not separate the clutch plates due to insufficent lift.Also some cable adjusters on levers do not fit the outer cable and may need to be modified.
Brett