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Old 04-07-2013, 07:32 PM
maniac57's Avatar
maniac57 maniac57 is offline
Old, Fat, and still faster than you
Join Date: Oct 2011
Location: memphis Tn
Posts: 4,486
Default Clutch lever repair

Do you have one of these levers with the notched locking lever?
The locking pawl actually saws through the cast post after a few thousand miles and the lever no longer holds the clutch disengaged when the lever is locked. See how the casting is almost sawn all the way through?

I cut a small bit of steel and bent it to fit the cast post where the locking pawl rubs and used some JB Weld to secure it to the casting so the pawl now rubs on steel rather than soft aluminum.

Best part of this repair is that it was free!
Plus it actually makes the lever work much better since it locks with the lever pulled in more so there is no clutch drag when pedaling.
If more is better, then too much is just enough.
If you can't afford it, build it yourself.
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Old 04-07-2013, 07:35 PM
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CTripps CTripps is offline
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Join Date: Aug 2011
Location: Vancouver, B.C.
Posts: 1,311
Default Re: Clutch lever repair

Nice fix. Even better for being free.


Any day that starts with a good ride is already a better day, and a bad day riding still beats a good day working.

My Builds: My Beast, Harley59's bike, my Cruiser
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Old 04-07-2013, 08:14 PM
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2door 2door is offline
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Join Date: Sep 2008
Location: Littleton, Colorado
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Default Re: Clutch lever repair

Great tip, Maniac. Sure beats buying a new lever. Thanks for sharing.

Have you tried putting a small rubber 'O' ring on the locking pin where the snap ring is? I use a 3/32 ID 'O' ring there. It really quiets the "snap' sound when you release the lock and sounds more precision. It also eliminates some of the shock to the snap ring.

I also eliminate the snap ring, drill through the shaft of the locking pin and install a 1/16" cotter pin. The snap rings are notorious for coming off and then you can loose the pin and spring.

Age and Treachery Will Always Triumph
Over Youth and Skill & "Charlie Don't Ride"
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