[kawidrew]

Hi, I have a 1981 KX250 and finding the OEM Clutch and front perch/brake levers isn't easy. I'd like to go with aftermarket but not having too much luck finding anything for this bike. Does anyone have any suggestions on what I should go with? I already bought some NOS hand grips and the throttle housing control but would like aftermarket levers/perches. Hopefully they are compatible with the NOS cables - I assume that's all standard anyway?

I saw this one here I really like by MSR on a 1980 KX250 but can't seem to find it online.

 

[bweighmaster]

Quite an assortment on EBAY ....

 

[james.htx]

In general, clutch perches aren't bike-specific, per-se. OEM clutch perches are of course sold as bike-specific b/c that's what came on the bike originally. So, just bc Kawi maybe doesn't still make a clutch perch for your bike doesn't mean there are no possible solutions.

What you're most likely looking for is something that fits 7/8" bar diameter. That's about the only critical spec for fitment. If your bike somehow has bars with a smaller diameter than 7/8" at the grip ends, then that's very odd and I have no suggestions.

The cable-end socket on the lever arm is a standard size, AFAIK. Maybe some really old bikes used a ball-end?... but every Japanese dirtbike I've seen since the 80s uses the 'barrel-end' type.

Amazon has a lot of options, as does Ebay like the other poster said.

Just be careful when you're buying something to check that you're getting the perch and the lever. The perch is what will have that big thumb-wheel adjuster like your pic shows. Also check that the lever/perch you're buying is for an offroad/dirtbike... b/c there's a lot of street-bike stuff for sale too. I mean, you could prob* use a streetbike setup, but it would look wonky and probably be less durable.

A lot of lever-only purchase options are out there b/c its a commonly broken item on a dirtbike, so folks often only need to buy just the lever. So if the pics in the ad only show the lever, be aware of this. You can buy a lever and a perch separately, but you have to be careful to make sure what you buy is compatible. Not all levers fit all perches.

You're safer just buying a lever + perch combo that has the thumbwheel feature you want. Lots of choices out there.

EDIT:
forgot to address your question about front brake. If it is cable operated, then I don't know what to tell you other than to Ebay-search for 'cable actuated front brake perch and lever'. I would think an 81 might've had front drum brakes, and so might be cable operated.


*just b/c I say probably, doesn't mean I guarantee it would work... so don't try this and then complain if it doesn't work... I'm just speculating.

 

[kawidrew]

In general, clutch perches aren't bike-specific, per-se. OEM clutch perches are of course sold as bike-specific b/c that's what came on the bike originally. So, just bc Kawi maybe doesn't still make a clutch perch for your bike doesn't mean there are no possible solutions.

What you're most likely looking for is something that fits 7/8" bar diameter. That's about the only critical spec for fitment. If your bike somehow has bars with a smaller diameter than 7/8" at the grip ends, then that's very odd and I have no suggestions.

The cable-end socket on the lever arm is a standard size, AFAIK. Maybe some really old bikes used a ball-end?... but every Japanese dirtbike I've seen since the 80s uses the 'barrel-end' type.

Amazon has a lot of options, as does Ebay like the other poster said.

Just be careful when you're buying something to check that you're getting the perch and the lever. The perch is what will have that big thumb-wheel adjuster like your pic shows. Also check that the lever/perch you're buying is for an offroad/dirtbike... b/c there's a lot of street-bike stuff for sale too. I mean, you could prob* use a streetbike setup, but it would look wonky and probably be less durable.

A lot of lever-only purchase options are out there b/c its a commonly broken item on a dirtbike, so folks often only need to buy just the lever. So if the pics in the ad only show the lever, be aware of this. You can buy a lever and a perch separately, but you have to be careful to make sure what you buy is compatible. Not all levers fit all perches.

You're safer just buying a lever + perch combo that has the thumbwheel feature you want. Lots of choices out there.

EDIT:
forgot to address your question about front brake. If it is cable operated, then I don't know what to tell you other than to Ebay-search for 'cable actuated front brake perch and lever'. I would think an 81 might've had front drum brakes, and so might be cable operated.


*just b/c I say probably, doesn't mean I guarantee it would work... so don't try this and then complain if it doesn't work... I'm just speculating.

That's some great info and really helps... thanks a lot!

 

[james.htx]

That's some great info and really helps... thanks a lot!

Pretty close to what your first pic shows. ProTaper is a solid brand. I've never used this lever or stuff from their 'sport' line (which is their more affordable stuff), but looks pretty decent to me just in the pic.

Amazon.com: ProTaper Sport R-1297 AIP33R AOF Lever and Perch Combo - Black : Automotive

Buy ProTaper Sport R-1297 AIP33R AOF Lever and Perch Combo - Black: Clutch - Amazon.com ✓ FREE DELIVERY possible on eligible purchases

www.amazon.com

 

[kawidrew]

Pretty close to what your first pic shows. ProTaper is a solid brand. I've never used this lever or stuff from their 'sport' line (which is their more affordable stuff), but looks pretty decent to me just in the pic.

http://[URL]https://www.amazon.com/...ix=protaper+sport+clutch+lever,aps,101&sr=8-4

[/URL]

 

[kawidrew]

I've seen that one before and would look great on my bike. The problem is I cant find a brake lever to match. It seems they just sell the clutch lever and perch only, unless I missed something.

 

[james.htx]

I've seen that one before and would look great on my bike. The problem is I cant find a brake lever to match. It seems they just sell the clutch lever and perch only, unless I missed something.

Yeah, that one is clutch perch and lever only.

When you say 'match', do you mean that the brake lever needs to have the speed-adjuster too?... are your brakes cable operated or hydraulic? If the latter, it won't have an adjuster like that ever. If cable operated, I still don't think I've ever seen a speed-adjust for cable-brakes. It just wasn't ever a thing back in the day of drum/cable-operated brakes.

So if its just aesthetics b/c you don't want a dogleg/modern lever on the left paired with the OEM 'banana' lever on the right, you're not going to find a modern type clutch-perch setup that has a speed-adjuster like these with an old-school type lever (non dog-leg) as was found on older bikes. I mean, maybe there's one out there, but I've never seen it.

Best you could try if you want that is to buy this ProTaper one, take the lever off, measure the pivot hole dia and the thickness of that pivot area and try to find a old-school looking lever that has the same measurements. The cut/angle on the lever has to match the perch too... they don't all have that same sort of cut-out area, especially mixing modern stuff with old-school stuff. Take a good look at the perch where the lever rests against it.. there's some angles there that need to match.

This kind of hybrid setup is gonna be iffy... you will prob wind up buying a few levers before you find one that fits. That's why I was saying what I said in my original reply that you're safer buying the perch + lever together if you just wanted something that worked w/out fuss.

You could maybe look for replacement brake levers that match the style of the ProTaper one (a dogleg), but unless it's made by ProTaper, it probably won't match exactly and may not fit the brake perch.

Or, if you're ok with having 2 dogleg/modern-looking levers, maybe buy a 2nd ProTaper clutch perch/lever and just flip it over for use on the brake side. The rubber cover would pretty much cover up any odd-looking stuff that normally faces 'down' I imagine. This is, again, assuming you have drum/cable operated front brake. If hydraulic, nevermind this isn't the solution.

I can't say I've ever tried something like that, nor do I know anyone that has. Surely someone has used a clutch setup as a brake setup for cable-operated brakes at some point? Or, maybe the brake cable-end is different sized and won't fit into the typical clutch lever end-recess?

You'd be a trailblazer for trying it. If you do, post your progress!


Having said all that...
There are a lot of old-school style clutch perch+levers out there that have a standard looking knurled adjustment-wheel setup though that will match your OEM brake lever, or near enough that only a real close inspection would find issues.

 

[kawidrew]

Yeah, that one is clutch perch and lever only.

When you say 'match', do you mean that the brake lever needs to have the speed-adjuster too?... are your brakes cable operated or hydraulic? If the latter, it won't have an adjuster like that ever. If cable operated, I still don't think I've ever seen a speed-adjust for cable-brakes. It just wasn't ever a thing back in the day of drum/cable-operated brakes.

So if its just aesthetics b/c you don't want a dogleg/modern lever on the left paired with the OEM 'banana' lever on the right, you're not going to find a modern type clutch-perch setup that has a speed-adjuster like these with an old-school type lever (non dog-leg) as was found on older bikes. I mean, maybe there's one out there, but I've never seen it.

Best you could try if you want that is to buy this ProTaper one, take the lever off, measure the pivot hole dia and the thickness of that pivot area and try to find a old-school looking lever that has the same measurements. The cut/angle on the lever has to match the perch too... they don't all have that same sort of cut-out area, especially mixing modern stuff with old-school stuff. Take a good look at the perch where the lever rests against it.. there's some angles there that need to match.

This kind of hybrid setup is gonna be iffy... you will prob wind up buying a few levers before you find one that fits. That's why I was saying what I said in my original reply that you're safer buying the perch + lever together if you just wanted something that worked w/out fuss.

You could maybe look for replacement brake levers that match the style of the ProTaper one (a dogleg), but unless it's made by ProTaper, it probably won't match exactly and may not fit the brake perch.

Or, if you're ok with having 2 dogleg/modern-looking levers, maybe buy a 2nd ProTaper clutch perch/lever and just flip it over for use on the brake side. The rubber cover would pretty much cover up any odd-looking stuff that normally faces 'down' I imagine. This is, again, assuming you have drum/cable operated front brake. If hydraulic, nevermind this isn't the solution.

I can't say I've ever tried something like that, nor do I know anyone that has. Surely someone has used a clutch setup as a brake setup for cable-operated brakes at some point? Or, maybe the brake cable-end is different sized and won't fit into the typical clutch lever end-recess?

You'd be a trailblazer for trying it. If you do, post your progress!


Having said all that...
There are a lot of old-school style clutch perch+levers out there that have a standard looking knurled adjustment-wheel setup though that will match your OEM brake lever, or near enough that only a real close inspection would find issues.

 

[kawidrew]

Intersting that you mentioned flipping it around. Do you think this is what this guy did in his resto? This is an '80 KX250, basically same as my 81.

 

[james.htx]

Intersting that you mentioned flipping it around. Do you think this is what this guy did in his resto? This is an '80 KX250, basically same as my 81.

Looks like that's what's going on in that pic. If you look at the brake-side lever, the pivot nut is 'on top', and on the clutch-side, the bolt-head is on top (which is the normal way). Also, you don't see the ProTaper lettering on the brake-side rubber-cover (b/c it's facing down).

 

[kawidrew]

Looks like that's what's going on in that pic. If you look at the brake-side lever, the pivot nut is 'on top', and on the clutch-side, the bolt-head is on top (which is the normal way). Also, you don't see the ProTaper lettering on the brake-side rubber-cover (b/c it's facing down).

Thanks for confirming. I think I have found my solution!

 

[james.htx]

Thanks for confirming. I think I have found my solution!

Sounds good bubba, Best of luck!

 

[kawidrew]

Sounds good bubba, Best of luck!

Thanks! I appreciate the help. Now I can sleep at night lol

 

[james.htx]

Actually, one more suggestion. If you have a set of calipers or just a good metal metric ruler and trusty eyes, try to measure the diameter of the clutch-side cable end and the brake-side cable end (the metal barrel-shaped dudes at the end of the cable). If they're the same (and I figure they are), then this should be a bolt-on.

But, just in case the brake-side one is larger, you might have to prepare to drill out the 'flipped-over' brake handle to accept the possibly larger brake-cable end. I doubt it would be much larger, a mm or so?.. if at all.

Just trying to think of things you may run into.

 

[kawidrew]

Actually, one more suggestion. If you have a set of calipers or just a good metal metric ruler and trusty eyes, try to measure the diameter of the clutch-side cable end and the brake-side cable end (the metal barrel-shaped dudes at the end of the cable). If they're the same (and I figure they are), then this should be a bolt-on.

But, just in case the brake-side one is larger, you might have to prepare to drill out the 'flipped-over' brake handle to accept the possibly larger brake-cable end. I doubt it would be much larger, a mm or so?.. if at all.

Just trying to think of things you may run into.

Should that happen then no problem will whip out the dremel. I would expect something might go wonky by flipping it around.