clutch lever for 1" bars

[chevy2tom]

What are you guys using with the stock cable & 1" bars? I can find them for 7/8 but not 1". Or what set up do you recommend? Nothing fancy just a simple set up. Thanks

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[TwoManyXS1Bs]

Hey chevy2tom, I recall seeing a vendor offering xs650 1" bar controls, just can't remember who it was. So, it's out there somewhere. If I remember it or find it, I'll post here...

 

[DogBunny]

You use a Harley Sportster or Dyna lever. I wrote a how-to on this back in 2009, which is here:
http://xs650temp.proboards.com/index.cgi?board=Frames&action=display&thread=13666
Scroll down to post #13 which shows how to modify the stock XS650 cable to fit in the Sportster or Dyna lever.

 

[chevy2tom]

Thanks, guys. Dog that's exactly what I'll do thanks for the tip.


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[PlugHead]

Great write up DogBunny. I have always liked Harley controls, so I might have to give this a try.

 

[DogBunny]

I think the biggest trick might be finding the steel spacer I pictured in post #13, shown again above. My Lowe's used to have a great selection of steel and nylon spacers in their specialty fastener drawers, but they don't carry most of them any more. Same with Home Depot. I think different stores in each chain have different selections.
Tapping the threads into the spacer is also a bit of a trick -- you need to vice or chuck the spacer tight enough to cut the threads but without collapsing the spacer.

 

[chevy2tom]

I'll look @ true value or ace hardware they have all that stuff or I'll go to a buddys tool & die shop & make one. Thanks again.

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[evil 650]

Hay DogBunny,
that's some awesome work, i'm doing something similar, 4" risers,1" bars, exile cycles internal throttle, and a grip ace hidden switch system, but i need a micro kill switch, would you happen to have a link to those micro switches you used?

thx

 

[DogBunny]

evil 650, when it comes to micro switches, you are looking for ones with the maximum amp rating. Radio Shack makes a fantastic two-position off/on toggle, part # 275-0324
http://www.radioshack.com/product/index.jsp?productId=2062485
It is rated at 10 amps/125VAC, which is really high for a micro switch. Highest rated I have found by far.

BTW, Radio Shack also makes a fantastic full-size toggle switch (actually a paddle switch):
http://octopart.com/275-024-radioshack-24527443
My package lists it as 275-0024. What's fantastic is that it is rated for DC instead of AC, and it is rated 30 amps which is huge. Has built-in red LED which is goofy, but otherwise makes a great ignition switch if you are going key-less, or as a secondary, secret, hidden kill switch (nice to have a secret switch if you go key-less like I do).

 

[evil 650]

thanks dogbunny for the links
im going to pick up couple and see if i can fit them into my plans for the handle bars