A few progress photos of the arm components being manufactured by Dan at DJ Design & Engineering. These look fantastic, and a big shout out to Dan for dialing in my tolerances and for the milling these out so quick.
Once complete these parts will be sent off to DNA Anodising - should look even better.
I think I have it now, and of course it was a $37 eBay part.
What I’m aiming for with the RH switchgear set is minimal width and the most amount of controls. Looks took a back seat on this one. I just needed to bring the clutch lever over as close to the handgrip as practical, and at the same time have the controls in easily operated positions.
The plan had been to use a separate throttle assembly and some LH side switchgear. With the throttle assembly width at 24mm it didn’t leave a lot of room before the clutch lever, and ultimately brake lever, were moved too far away. And this is why I was shelling out for compact switchgear like the K&S gear.
I took a gamble on this set from eBay as it included a throttle tube housing - with the right attachment point for the SWM throttle cable. Quality overall isn’t too shabby; aluminium housing, switches seem fine even if their fit in the housing isn’t perfect. There is a small locating pin on the rear shell of the housing which will have to, if it doesn’t align with what is on the handlebar now. The current labelling will have to go, and hopefully replaced.
Overall width is 48mm, or 44mm if I trim down a small lip to the left hand side of the housing. Assuming I take out the lip this assembly brings my clutch and brake levers 11mm toward the throttle grip. Real Estate on the handlebar is hard to come by with all of the controls in one place, so 11mm is a significant win.
Wiring this up will mean repurposing the 3 position headlight switch as my turn signals. Fortunately, the switch has the right contacts and wiring and should work. The starter button will become the horn switch, and the kill switch will become the hi/lo switch for the headlight. The plan being to wire all of this in while retaining the bikes standard LH side switchgear. Start and kill switch are in a separate housing, bolted to the back of the clutch lever perch.
I’ve abandoned the two functional clutch levers setup I was so keen on. Instead, I’m running a bit of a compromise; the original clutch lever and cable remain and can be easily changed over for a two-armed rider. I’ve added two cable clamps; one to keep the second clutch cable up and out of the way (more presentable) and a small clamp to tie the two clutch cable inners together. The two cable inners operate together to activate the clutch switch.
The original front brake lever is replaced by a short brake lever to improve my emergency stops; index and middle finger operate the brake while ring and little finger operate the clutch lever. Seems to work so far.
360 degree video of the clutch being punished.
Two clutch cables and clamps.
Clutch and brake lever set up.
Current state of the handlebars and controls.
The latest two switchgear options.
First one is a full set of K &S Technologies switchtgear. Part numbers 12-0055 and 12-0055CN. Check them out HERE . I bought these through eBay from Alchemy Parts in the UK. These were not cheap, but the quality is worth it. Total cost $145 AUD.
The second contender appears to be a cheap knock off of the K&S Tech part. This set isnt terrible though. the housing is cast aluminium, the wiring isn’t too bad and the switches (though cheesy looking) appear quite robust. The indicator switch on this set feels more positive and natural compared to the K&S set. Total cost $16 AUD.
These two fill the gap between being compact and appearing intuitive. Both house only three of the six switches required and will leave me to fill out the starter button and kills switch using the 2 x switch housing from eBay. This thing isnt too bad either, bulky and weird looking but well made. I’ve switched out one of the red latching switches for a green momentary switch (starter) leaving the remaining red latching switch as my Kill switch.
The Pass switch is the only switch I have left to sort out, and to be honest I’m going to try wing it without ia Pass switch.
I have three other options on their way before I make a decision on which way I’m going with this.
K&S Technologies switchgear.
Inside look at the K&S Technologies switchgear.
Cheap eBay switchgear
Inside look at the eBay switchgear.