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This is the finished product new actuator, modified with the cut, slight bend and weld on the inside (leading edge). You can see the very slight dogleg bending towards the front.

Didn’t spend any time polishing or smoothing it out really. Just light grinding and silver paint.
Feels better than a hydraulic in my opinion. Bike is dirty from trail riding earlier today.

Nice, thank you for sharing! I am still a little unsure what exactly you mean by the dogleg and bend and everything, but I feel like its going to be become pretty apparent once I start messing with it. The photo definitely helps! I have a used one on order, so I'll let you know how it goes. I didn't have any luck finding one for a 1993 KX125, unfortunately, so figured this was the next best thing.

See if this helps, cut was to the inside, heated and then closed on itself to create the very slight dogleg that shortens the distance the cable needs to reach and connect. Otherwise your cable will be too short and it’s always pulling on the actuator.

ahhhh hah, I gotcha now, that makes sense, thank you for clarifying.

Would you happen to have this measurement handy that you could share from your finished product (linear distance between circles):

I could take a measurement when I get home from this trip. Might be later this weekend.

No worries. I got my used in and extended it over the weekend. I measure a linear distance of about ~37mm from centerline to centerline, was originally ~27mm. The little extension piece I made was a trapezoid lol measured 12mm long at the top and 10mm long at the bottom to give it a dog leg. In the process of doing this, I found my clutch cable was fraying at the end! So looks like I need to replace that too... anyways:

Standard vs. Extended Before After Figured I'd give her the ole one finger shorty clutch lever mod while I was at it too Took it for a spin around the neighborhood and worked great. No issues that I could tell and was super light pull. Using a pull type luggage scale, the pull looks to have went from ~8lbs to ~5lbs, definitely one-fingerable. There is some play in the lever and the amount of pull needed to fully engage doesn't seem to have really changed. Ended up adding one washer where the cable mounts to the engine case to take up some slack. Seems to be pretty straightforward other than that. Thanks for the tip on the dogleg, saved me some time there. Going to put heavier clutch springs in and will report back. I am liking it so far, kept the stock one on hand incase I want to go back for whatever reason.

Nice job! It’s amazing how much more pleasant this mod has made technical riding. With the Streamline clutch lever and the stronger EBC springs it’s made the bike better all-around.

Nice, I'm excited to get it into the woods and see for myself!

Going to visit my buddy SS109 in a couple weeks to get some riding in, so figured I’d go ahead with this mod so he will let me ride with the cool guys! I am going to extend the pivot point by 10.0mm

Decided to make a replacement lever for the clutch actuator. Grinding off the stock welds, the assembly comes apart.
I got to work on the lathe, and made a new pivot pin. The hole for the stock pin was all wallowed out on my arm, so made it a pretty tight fit to remove any slop in the line. Had a scrap piece of steel, so some quick work on the mill and I had a new piece.
Got the new arm aligned, welded up, and bead blasted before it was into the zinc plating tank. Decided to do the spring in yellow chromate.

Got the cover reinstalled, and I’m quite happy with the easier pull so far.

Cool guys, LOL!

Nick, you always go to the max on your work. You always manage to inspire me to up my game.

GREAT WORK! Looks awesome.

Very nice!
Did you use a tooth brush and duraglit on that engine?
I may need some sunglasses to look any closer.

Thanks everyone! Nope, just standard simple green Pro HD (the purple stuff) it’s aluminum safe and makes it glisten! Also pretty anal about washing it right after I get it dirty too.

Nice work! Man, I'm going to have to go back now and do mine again better That would be sweet to have the ability to plate things like that.

Tyl3r wrote: ↑05:45 pm Jan 29 2023 Nice work! Man, I'm going to have to go back now and do mine again better That would be sweet to have the ability to plate things like that.

I use the Caswell stuff it’s actually quite affordable.

Nick, if you’d just move south of the border we’d keep you busy plating and machining all our stuff! … but then again our summers are too long and you’d end up riding too much to get the work done!

Thanks for the SG Pro HD tip, will try it.

Almost a year has passed since using J-B Weld as described above. It is not possible to provide a report for how the epoxy is holding up. Very few miles have been ridden since the epoxy appliction because the Nat'l Forest Service temporarily closed "my" riding trails due to Winter 2022 storm damage. "They" finally re-opened one of them about 2 weeks ago. But, the shortest county road route to it remains closed due to non-repaired storm damage.

billie_morini wrote: ↑12:04 pm Sep 07 2023 Almost a year has passed since using J-B Weld as described above. It is not possible to provide a report for how the epoxy is holding up. Very few miles have been ridden since the epoxy appliction because the Nat'l Forest Service temporarily closed "my" riding trails due to Winter 2022 storm damage. "They" finally re-opened one of them about 2 weeks ago. But, the shortest county road route to it remains closed due to non-repaired storm damage.

We'd definitely love to hear your long term update once you have access to all of your trail system...have really been enjoying this thread and want to do the same mods to my 200.

I seen this on a trial website from England. Someone with tools and skills (Slick Nick) could make these and sell them to us.

Trials Bike Parts :: Engine & Transmission :: Honda TLR200 / TLR250 Clutch Actuating Arm Extension / Lightener

If that link doesn’t work then someone tell me how to attach a photo.


Thanks
Steve