Clutch lever repair

Discussion in 'Motorized Bicycle General Discussion' started by maniac57, Apr 7, 2013.

  1. maniac57

    maniac57 Old, Fat, and still faster than you

    Joined:
    Oct 8, 2011
    Messages:
    4,486
    Likes Received:
    7
    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?
    [​IMG]
    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.
    [​IMG]
    [​IMG]
    [​IMG]
    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.
     
  2. CTripps

    CTripps Active Member

    Joined:
    Aug 22, 2011
    Messages:
    1,311
    Likes Received:
    0
    Nice fix. Even better for being free. (^)
     
  3. 2door

    2door Moderator
    Staff Member

    Joined:
    Sep 15, 2008
    Messages:
    16,310
    Likes Received:
    38
    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.

    Tom
     

Share This Page