With boots on, I can't get my left foot comfortably under the shift lever. Raising the lever one spline moves the lever too high, I have to lift my foot off the peg to shift. Has anyone had this problem and, how did you fix it? I have looked for aftermarket levers there are none. I've thought about bending or heating & bending the lever, if I have to.

 

Mate, I had to do the same to mine. It was also compounded by the fact I also purchased new off-road boots that were stiff at first. Now they've broken in some, I've lowered the lever on the spline a touch.
I still have to lift my foot slightly to change gear, but I've got used to it.
The stocx position isn't good. Pretty much the only real crticism I have with the bike.

 

dammit. i just did a writeup on changing the heights via the spline.. in the middle, i re-read your posts, and i saw you've already tried thet..

and i'm a retard.. lol

Hmm..might have to just tweak it a tiny bit.

i'm not sure about heating the metal up, as i'll assume its a cast aluminum.. that'll soak up the temper and it'll be uber weak then.. if you're crafty, ya might be better off chopping it at an angle and welding it inthe position of a favorable offset..

just my $.002

 

The lever is steel, you can cut and weld it.. Rumor has it a lever from a KLX140 will fit!

 

The lever is steel but a vice and an 18" pipe wrench work wonders. I bent the lever 1/2" and got the clearance that I wanted. Cheap but effective fix.