KLX300 Short Levers

[Glenn McMullin]

I’m trying to find short levers for my 2022 KLX300 Dual Purpose. The pinky on my left hand is permanently bent at 90 degrees and gets in the way of the clutch lever when I pull it. I don’t want to spend $100 per lever for the fancy adjustable ones, I’m hoping to find some basic aluminum levers that will activate the start in gear and brake light switches. Does anyone have any ideas? Thanks in advance, Glenn

[The Agitator]

As a suggestion you  could take the lever off, put it a vice, cut off excess, smooth with a file and add some wraps of tape or shrink tube cover the end.

You could also gently bend the end, out/forward.

Both sort of hard to describe and I think I have pics of both options from my bikes but I'll have to look on my computer or take pics later

 

[kdxyardsale]

Check the internet for this brand MZS, they make several varieties for each bike, and also look at the fitment as many of our off road Kawi levers, are a direct fit for streetbikes (my '12 KLX250 is the same lever and the 250 crotch rockets)

I have these on both my '12 KLX250S and my Yamaha '21 MT-07, they fit and work very well. The basic versions are just the lever, it works with the brake light and clutch switches and I have not had one issue with them, you may have to reuse the stock spacer for the bolt.

https://www.amazon.com/MZS-Clutch-KLX230-KLX230R-KLX300/dp/B0957B6ZPF

[Glenn McMullin]

Thanks for the suggestions. The only company I can find that actually lists a part for my bike is ASV. It looks like I may have to spend a bit more than I hoped. 

[SuperHonkycross]

Moose E-Z Pull clutch perch and lever may work for you. They have a short lever version that isn’t expensive at all. You’ll have to bypass the clutch switch or fabricate a way to mount it though as there is nowhere to put the switch.

As far as a brake lever goes, you could use one from an off-road model. The stock lever on my old 300 was quite short from the factory. I am not sure how the brake light switch works on the KLX300 dual sport, but if it is mechanical you could simply install a banjo bolt hydraulic switch type. I did this on my KLR when I swapped the forks and it works great. 

[kdxyardsale]

On 12/3/2021 at 2:52 AM, Glenn McMullin said:

Thanks for the suggestions. The only company I can find that actually lists a part for my bike is ASV. It looks like I may have to spend a bit more than I hoped. 

So you know, I bought my 2021 Yamaha MT-07 in early summer of 2021. I contacted MZS to see if the '20 levers fit as they did not list a fitment for the '21. They said they had not tested them yet or the new model. Most of the aftermarket and factory sites do not even have parts fiche online yet to compare part numbers for your 22.

I ordered the '20 MZS levers from Amazon as their returns are super easy and quick to get your money back, usually once the shipping tracking starts. The '20 MZS levers fit my '21 MT-07 perfectly. The KLX300 changes from appearance in photos looks identical and perch/levers is not something that factories usually changes very often.

I would try ordering '21 MZS levers and test fit, compare them to the ones on your bike side by side. I would bet they fit perfect. If not send them back.

[Glenn McMullin]

Thanks again for the suggestions. I will post a picture of whatever solution I decide on. 
Glenn

[Glenn McMullin]

In the end I went with MZS. The levers fit properly and seem to be well made. ASV prices are just too high, it would have cost over $300 for a pair delivered. MZS cost under $60 Canadian delivered. They are a little chunky feeling compared to the OEM levers but I will soon get used to that. It’s too bad a North American company can’t make a competitively priced product. 

[Glenn McMullin]

So after a month of the riding season, I’m back to the stock levers. The MZS brake lever resulted in a spongy feeling brake because the contact with the brake plunger occurs later. The clutch lever, while shorter, still required at least 3 fingers or pulling against the fingers that remained on the bar. They were also fatter, also resulting in less room for fingers behind the lever. I may just buy a second set of factory levers , cut them short and weld a ball back on them. The search continues. 

[brianq103]

On 5/14/2022 at 5:52 PM, Glenn McMullin said:

So after a month of the riding season, I’m back to the stock levers. The MZS brake lever resulted in a spongy feeling brake because the contact with the brake plunger occurs later. The clutch lever, while shorter, still required at least 3 fingers or pulling against the fingers that remained on the bar. They were also fatter, also resulting in less room for fingers behind the lever. I may just buy a second set of factory levers , cut them short and weld a ball back on them. The search continues. 

I noticed the mushiness as well. I bought teh same brand for my Tenere 700 and they were also mushy. However, what I figured out with those was that the "cup" they use to capture the brake actuator pin is too deep, so I was able to epoxy a shim at the bottom of it and now the Tenere brakes are perfect. I will be attempting the same thing with the KLX to see if I can make them work.

[Glenn McMullin]

I ended up cutting a lever short enough that just two fingers contact it. It works very well. I bought a second stock lever, shortened it then welded the ball back on but the ball then jams against the fingers that are still in contact with the bar. I have a condition known as dupuytrens contracture that curls the last two fingers of my hand. The joys of aging I guess. 

[Guest]

5 minutes ago, Glenn McMullin said:

 

I have a condition known as dupuytrens contracture that curls the last two fingers of my hand. The joys of aging I guess. 

Sorry to hear that. I'm 62 and got Lyme disease a few years ago and have been going downhill with arthritis-like symptoms ever since....even though it's not certain it's related to Lyme. I bought a Ninja 400 on March 10 but will be getting a KLX this year and likely trading the Ninja in. I'm feeling a but of a sense of urgency. I might be fine for a couple more decades but I might only have a couple years of riding left. Since I don't  know,  I'm having as much fun as I can now. I'm loving the Ninja because I've never owned a sport bike but I'm missing a dual purpose.

[Glenn McMullin]

Maybe we should start an old guys riding forum. All the hacks that keep you riding into the sunset.