Help, I can't get brake or shift lever low enough. - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

 9Likes
  • 1 Post By Tom Schmitz
  • 1 Post By Tom Schmitz
  • 4 Post By GoMotor
  • 1 Post By DPelletier
  • 1 Post By Tom Schmitz
  • 1 Post By Bluehighways
 
LinkBack Thread Tools Display Modes
post #1 of 10 Old 09-27-2017, 06:36 PM Thread Starter
2nd Gear
 
Candubrain's Avatar
 
Join Date: Aug 2017
Location: Kincardine, ON, Canada
Posts: 158
Help, I can't get brake or shift lever low enough.

Bike: 2016 KLR 650

Me: 6'5" tall, 36" legs, size 13 boot, 210 lbs

Just installed the JNS Engineering foot peg lowering kit.

I've adjusted the brake lever as low as it will allow, and I've rotated the shift lever to the point it almost touches the frame tube when downshifting. Neither lever is low enough, I have to raise my foot off the peg to either downshift or brake.

My legs are so long that my ankle is bent up almost as far as it can when my foot is resting on the peg in a seated position. This is preventing me from lifting my foot any higher to downshift or brake without first lifting my foot slightly off the peg.

I've googled the forum and internet looking for an answer or alternative levers, but have come up with nothing.

Can either lever be heated and bent? Or do I need to buy an all steel lever to do so?

Any suggestions greatly appreciated.

thanks
brian
Candubrain is offline  
Sponsored Links
Advertisement
 
post #2 of 10 Old 09-27-2017, 07:28 PM
Pretty in Pink, dunno why
 
Tom Schmitz's Avatar
 
Join Date: Feb 2009
Location: Redondo Beach
Posts: 7,924
Garage
Quote:
Originally Posted by Candubrain View Post
...Me: 6'5" tall, 36" legs, size 13 boot, 210 lbs...
You need to visit more BBQ joints.

The shift lever is steel, so it can be bent.

On the latest models I believe that the brake lever is steel. They used to be aluminum. Check it with a magnet to be sure it is steel. If it is, it can be bent.

Now, for some cockamamie advice.

It might be that a taller seat would do you some good. Get two bath towels and roll them up, set them side by side under your skinny butt and go for a ride. If that helps it is pretty easy to get some hard foam added to the seat and a new seat cover made.

This I am not sure of, but the Gen 1 brake levers might have been a tad lower than the later ones. If I can remember where I put my Gen 2 brake lever (I have not had great success with this sort of thing this week) I'll do a side-by-side and let you know. Might be an option.

There are longer shift levers available and many folks find that the longer lever solves the problem. I think Moose makes one. The down side to them is that they stick forward of the recess in the case where they are supposed to sit, so an impact to the shift lever can strike the case. If you go that route make sure that the lever you choose has the disk on the case side of the lever to help avoid punching a hole in the case.

With that, I'm off to find a Gen 2 brake lever...
Candubrain likes this.

Tom [email protected]

“I still held his automatic more or less pointed at him, but he swung on me just the same. It caught me flush on the chin. It was meant to be a hard one, but a pansy has no iron in his bones, whatever he looks like.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

Sting like a butterfly.
Noli Timere Messorem
Tom Schmitz is online now  
post #3 of 10 Old 09-27-2017, 08:00 PM
Pretty in Pink, dunno why
 
Tom Schmitz's Avatar
 
Join Date: Feb 2009
Location: Redondo Beach
Posts: 7,924
Garage
This might work for you. I've lined these up to the pivot, spring hole and the clevis. The Gen 1 brake lever looks to be an inch or more lower than the Gen 2. And, I have the Gen 1 lever adjusted as high as it will go.



They have the same part number, 1987 through 2007, so they should be fairly easy to find on e-bay.

Mind you, this information comes from a universe of 1, so they are either made that way or mine is bent. Mine does not look to be bent; it's pretty cherry. Had to throw that caveat in there, though.

Here's the least expensive one on the Canadian e-bay. Watch out; I saw one that was cheaper but it had no clevis bar on it. Might be a mis-listed part.

2003 Kawasaki KLR650 KLR 650 Rear Brake Pedal Lever | eBay
Candubrain likes this.

Tom [email protected]

“I still held his automatic more or less pointed at him, but he swung on me just the same. It caught me flush on the chin. It was meant to be a hard one, but a pansy has no iron in his bones, whatever he looks like.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

Sting like a butterfly.
Noli Timere Messorem

Last edited by Tom Schmitz; 09-27-2017 at 09:11 PM. Reason: I've saw? Sheesh...
Tom Schmitz is online now  
 
post #4 of 10 Old 09-27-2017, 08:00 PM
4th Gear
 
GoMotor's Avatar
 
Join Date: May 2014
Location: Texas
Posts: 1,260
On my gen2 KLRs both levers are steel. They are not exactly shaped right (long side vertical) for bending. Consider cutting and welding in a drop down piece. Or, cut part way through, bend down and weld a scab on the side. A muffler shop should be able to do the job quicker/cheaper than a dedicated welding shop.
GoMotor is offline  
post #5 of 10 Old 09-28-2017, 09:46 AM
5th Gear
 
Join Date: Aug 2010
Location: Kelowna, B.C.
Posts: 2,619
....I've heard this before but didn't realize the Gen2 lever was higher (good job Tom!) .....not sure if BOTH the aluminum and steel Gen2 levers are the same either.

Anyhow, you can try different levers, try modifying the one you have (if it's steel) like GoMotor suggests OR, you could sell the JNS brackets and go with the KnightDesigns drop pegs; these ones should drop enough to help ergos without dropping enough to cause the problem you're experiencing now. Knight Design Kawasaki KLR650 11-16 Wide Foot Pegs

There was a big discussion on these "elsewhere" and it was determined talking to the manufacturer that the 3/8" drop pegs (the ones I use) for the Gen1's are the same dimensions as the 3/4" drop pegs for the Gen2's. I've heard of some Gen2 guys having the same issue you are with the KnightDesigns 1 1/8" / 1 1/2" drop pegs. The JNS brackets say they are a 1.5" drop.

Cheers,
Dave
Candubrain likes this.
DPelletier is offline  
post #6 of 10 Old 09-28-2017, 10:04 AM
Pretty in Pink, dunno why
 
Tom Schmitz's Avatar
 
Join Date: Feb 2009
Location: Redondo Beach
Posts: 7,924
Garage
To be clear, the Gen 2 brake lever pictured above is an aluminum 2009. I have no idea what the shape/configuration of the steel brake lever is.
DPelletier likes this.

Tom [email protected]

“I still held his automatic more or less pointed at him, but he swung on me just the same. It caught me flush on the chin. It was meant to be a hard one, but a pansy has no iron in his bones, whatever he looks like.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

Sting like a butterfly.
Noli Timere Messorem
Tom Schmitz is online now  
post #7 of 10 Old 09-28-2017, 10:20 AM
4th Gear
 
GoMotor's Avatar
 
Join Date: May 2014
Location: Texas
Posts: 1,260
Quote:
Originally Posted by Tom Schmitz View Post
To be clear, the Gen 2 brake lever pictured above is an aluminum 2009. I have no idea what the shape/configuration of the steel brake lever is.
In my post above I said both levers are steel. I should have mentioned that I was checking my 2011.
GoMotor is offline  
post #8 of 10 Old 09-28-2017, 03:57 PM
2nd Gear
 
Join Date: Mar 2017
Posts: 389
Size 13's here as well, although "only" 32" inseam. I was able to achieve satisfaction on my 2007 Gen 1 by using the JNS Lowering Peg Brackets, with really low cost (Chinese?) eBay sourced Off Road Pegs and an IMS extended Shift Lever. I did not need to make any changes to the stock aluminum Brake Lever.
Bluehighways is offline  
post #9 of 10 Old 09-28-2017, 06:55 PM Thread Starter
2nd Gear
 
Candubrain's Avatar
 
Join Date: Aug 2017
Location: Kincardine, ON, Canada
Posts: 158
Can't figure out how to thank everyone individually, especially Tom for the photos. Thank you All!

Some great ideas, I agree with Gomotor that bending these down would be difficult and might need some cutting and welding instead. Might buy some used levers and have them modified.

In the mean time, I'm taking off the JNS relocation brackets, they are a hazard especially for braking.

brian
Candubrain is offline  
post #10 of 10 Old 09-29-2017, 11:19 AM
2nd Gear
 
Join Date: Mar 2017
Posts: 389
Not sure if it'll help but here are some pictures of mine. Due to the angle of the camera it may look like the brake pedal is above the foot peg, but the reality is that it's just slightly lower than the foot peg. With my foot flat on the peg I'm not quite touching the brake pedal.
Candubrain likes this.

Last edited by Bluehighways; 08-31-2018 at 01:20 AM.
Bluehighways is offline  
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Kawasaki KLR 650 Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
Thick Winter Boot Shift Lever Turtle Man KLR & Other Motorcycle Related Discussion 10 10-21-2015 11:08 AM
Bent shift lever cause for concern on a used bike? imthedude KLR & Other Motorcycle Related Discussion 6 09-28-2011 05:24 PM
Broke Clutch and Shift Lever kmbsar 2008+ KLR650 Wrenching & Mod Questions 8 10-15-2010 10:28 PM
Best non-gouging shift lever wh4tig0t 1987 to 2007 Wrenching & Mods 10 05-06-2010 11:20 AM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome