Stuck on Clutch Lever Replacement (did brake one though) :D

[freelancer2011]

Hi Everyone!

I guess this is my first post (will write an intro soon).

I've had to replace my brake lever as after dropping it, twice (stationary/very, very slow speed, if at all), the lever was bent. I've done the brake lever and very relieved, more than anything.

I'm struggling with the clutch, however. Basically, I can't seem to get much give in order to get the lever out, so that I can remove the main screw (No. 3 in the diagram below) and the brass bushing (No. 4).

http://www.ascycles.com/Illustrated_catalog2/MicroList.aspx?id=51596&catID=32&catname=Steering&bindName=Clutch_control_assembly&bindCat=32_1767

That diagram doesn't even seem to depict just how chunky the clutch lever is! Anyway, I've got a 2008 F650 GS and I've got the heated grip with the ABS button. Do I have to remove the whole grip in order to remove the lever? Or should I just tug hard on the clutch cable so that I can get the lever out?

I've got a picture, should I post it here?

Thanks,
Lab.

 

[Smythson]

Hi and welcome!

I've not replaced a lever on this bike but did (twice!) on my 125. The clutch springs do put a lot of pressure on the cable. To get an idea - about 6 inches above the left footpeg you'll see the other end of that cable and the small lever it's attached to. Try pushing it and you'll get an idea of whether it's the pressure via the cable that's stopping the screw coming out. I take it the nut (no.5 in diagram) is off? If you wedge something behind the small lever on the engine end it will relieve the pressure and give you a bit of slack at the top end, hopefully allowing that screw to be released.

If this doesn't work then it could be that the screw has been bent, though i'd think this unlikely as the levers are designed to bend a bit to prevent damage to the main of the controls. If this is the case maybe a thin punch (of reverse end of masonry bit) may do the job...

A picture can't hurt - normally done by hosting in photobucket, or similar, then pasting link here.

Hindsight being a wonderful thing... handguards cost about the same as two OM levers. Mine's for road use and i still have them - paid for themselves a couple of times over

Best,

S

 

[freelancer2011]

Cheers Smythson (and for the tips from another thread recently, 'new F650 spied' ).

Will deffo' bear all of the above in mind. Thinking about getting the OEM levers. The new ones though 'adjustable and extendable' feel like a bit of a reach for me (baby hands)

I think I will try my best to upload a pic as basically I can't even get the lever off. Yes, the nut (No.5) and screw can be removed but I can't even slide the lever out. It keeps catching against the grip's plastic housing. -I should have said that straight away.

The guys at work mention that I should measure the amount of freeplay of the cable and now I'm wondering if I do eventually get the clutch lever out, will the cable suck it all the way into the housing? :O

 

[Dean]

Hello and welcome Lab

good luck with the mending


You deff need some of these here lever protectors.......

My old BMW F8/F650 ones

 

[Smythson]

Ah ha - with that screw out the only thing holding the lever on should be the pressure from the cable. Don't worry about it slipping back through - it has soldered nipples (check out the Bowden cables parts listing on your above link) on the ends to it will only slip so far. The pressure can be released from the footpeg end as above.

Other than that i'm stumped...

S

 

[freelancer2011]

Thanks again, guys. I think I will get some protectors to save all this trouble in the future

Basically, looking at this diagram:
http://www.ascycles.com/Illustrated_catalog2/MicroList.aspx?id=51596&catID=32&catname=Steering&bindName=Handlebar_grip,_heated&bindCat=32_1982

The housing (No. 5) of the clutch's handle is pretty thick and it's stopping me from sliding the clutch handle out. Is it a case of wiggling and persevering? It looks like if I did that, I would leave scuff marks on Part No. 5. -It's just that I don't see any way round it (though I'm a newb ) other than to take the whole grip off. Again...worried I might be unscrewing a whole lot of springs, bells and whistles.

Or is that really all that there is with the grip, as depicted?