ASV Clutch Lever - Kawasaki Ninja 1000 Forum
 
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post #1 of 8 Old 08-07-2019, 09:24 PM Thread Starter
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ASV Clutch Lever

I bought the ASV Forged Clutch lever and its installed and is great but its not fully triggering or i guess untriggering the clutch sensor. At first I was wondering why I couldnt start the bike in gear and then I realized I just did the clutch and i tested it by pulling on the lever after extending it backwards and the bike did start.

anyone else with asv levers that had this issue or know how to fix it? i have a 2019 if that matters.

thanks
ps. my lever didnt come with instructions, i am wondering if it was supposed to and it has the info i need

Last edited by bandroidx; 08-07-2019 at 09:27 PM.
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post #2 of 8 Old 08-07-2019, 10:27 PM
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For starters, do you have the correct clutch lever application? The 2017+ Ninja 1000 clutch lever is not the same as previous model years, they are not interchangeable. What ASV produces for these bikes, I have no idea.
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post #3 of 8 Old 08-07-2019, 11:15 PM
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The old and new levers are so different, it really would not be possible to switch them.

Look at the clutch switch, itself. It's made of the finest quality plastic and is very easy to damage. It's a round cylinder that gets depressed when you pull the lever in. Make sure it's still there, as it's easy to break. Look at when, or if the lever contacts the plunger. Se if it lines up, or pushes the plunger far enough.

This perch is new to the ninja 1000, but it's really old. It was in use as far back as 2006, and maybe even earlier. Asv probably realized this and used an existing lever from their stock.
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post #4 of 8 Old 08-09-2019, 10:11 AM
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I have the ASV levers (clutch and brake) on my 2018, which uses the same levers as the 2019. I haven’t had any issues with the switch engagement. Maybe post a pic so we can see what it looks like?
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post #5 of 8 Old 08-09-2019, 05:13 PM Thread Starter
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ok the issue is the plunger needs to come out like half a mm more. I think the issue is i have the clutch adjusted close to the bars, so with the new clutch it hits the handlebar before it releases the plunger that last mm. its a release plunger type when the clutch is pulled.

i am going to just adjust the lever to be a little further from the bar and i think that should resolve it. the other option would be to file a tiny bit of material off the plastic plunger.....\
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post #6 of 8 Old 08-11-2019, 03:51 PM Thread Starter
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Quote:
Originally Posted by bandroidx View Post
ok the issue is the plunger needs to come out like half a mm more. I think the issue is i have the clutch adjusted close to the bars, so with the new clutch it hits the handlebar before it releases the plunger that last mm. its a release plunger type when the clutch is pulled.

i am going to just adjust the lever to be a little further from the bar and i think that should resolve it. the other option would be to file a tiny bit of material off the plastic plunger.....\
I am able to get it to start in gear if i adjust the clutch to be further away frokm the bar, but now its too far away for max comfort. i think i am going to try to file a little bit of the plastic away on that plunger.....
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post #7 of 8 Old 08-12-2019, 12:54 PM
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Since I switched to a Brembo master on my 2013, I have a ASV front brake lever sitting in my parts box doing nothing. Make me an offer.............

BRC511-K-ASV C5 (black with red adjuster)
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post #8 of 8 Old Today, 05:47 PM Thread Starter
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i took a pair of snips and trimmed the plastic plunger in like half and now it works perfect. i realized riding around like that is seriously dangerous cause I could stall in a bad situation and not be able to restart the bike w/o first finding neutral. could be dangerous taking off in a busy intersection.
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