68 replies to this topic

[DaveW]

Not the usual question about cable adjustment but still (probably) a stupid one. I have wear in the end of the lever and the holder which is allowing vertical movement  as the lever is pulled. Obviously the correct thing to do would be to replace both - which I will do asap. 

My question is, could a temporary fix be achieved by withdrawing the bolt and inserting fibre/rubber washers either side of the lever within the holder? Or.....is there something fundamentally wrong with this that I'm too stupid to have thought of?

Thank you. 

(This wouldn't be a problem if I didn't have hand-guards which the lever now snags on if it happens to be a bit lower than normal when pulled.)

[itchyfeet2]

I can't really see a problem with your idea, as long as the washers inner hole diameter is a match for the bolts size. The other thing i'd bere  in mind is the outer diameter of the washers must be greater than the distance the lever can travel while opening. Otherwise there is the potential for the lever to catch when it tries to return leaving you with no drive. 

I would just go on eBay tbh as a new lever is not that expensive although I do appreciate not everyone has cash to spend.

 

itchy

Edited by itchyfeet2, 20 February 2021 - 07:51 pm.

[dablik]

If your clutch lever has a bush innit, seems some do and others dont, try tapping the bush out and reverse for a short term fix, washers wont last, tried that in the past, it's one part of the tdm i hate, replaced most of my clutch perches with kawasaki as much more robust..

[DaveW]

Thank you for the comments. Very helpful.

[DaveW]

Sorry all another related question.

Got the bits and about to replace lever and holder. I will need to get the grip off obviously. It is an aftermarket heated jobbie. Any tips on how to get it off without causing damage to the heating elements inside.

Thanks once again.

[fixitsan]

Sorry all another related question.

Got the bits and about to replace lever and holder. I will need to get the grip off obviously. It is an aftermarket heated jobbie. Any tips on how to get it off without causing damage to the heating elements inside.

Thanks once again.

 

Try switching them on to full heat for a while and then try a forceful twist. The heat can sometimes soften the adhesive

[DaveW]

Thank you. I'll try that.

[Atesz792]

Dablik (or anyone really), could you elaborate on what Kawasaki bike's clutch perch & lever fit the 9er? I have the same problem, and would like a definitive fix.
Thank you!

[DaveW]

Atesz792
Fyi. Having now done the job can I warn you that the clutch cable (on my 4TX at least) will happily spring out of its seating when you separate the switchgear. It's a nightmare to get it back in place!
I got new Yam bits from Fowlers.

[DaveW]

Sorry. Correction to last post. I meant choke cable not clutch cable!!!!

[Atesz792]

Thanks for the response, but no choke cable on a 9er. Also looks like I should be looking for a Kawasaki part that fits.

[dablik]

Dablik (or anyone really), could you elaborate on what Kawasaki bike's clutch perch & lever fit the 9er? I have the same problem, and would like a definitive fix.
Thank you!

 

I've used a clutch perch and lever from a ZZR600, the clutch lever is adjustable also, this was on a previous 900 and 850, in the knowledge base someplace is a write up where i think they used an kawa ER5 perch also.

[Atesz792]

Thank you!

[dablik]

 

Found another 900 pic

Edited by dablik, 11 March 2021 - 05:01 pm.

[Atesz792]

Thanks, looks great!

[Atesz792]

https://www.motea.co...black-a050192-0

Sorry if posting external links is against the rules. Feel free to delete if so.
So how about this one? Considering it is sold in pairs it is actually cheaper / piece than the one scratched up used ZZR clutch perch & lever I managed to locate nearby.

[Studley Ramrod]

External linkydinks are fine so long as they're spam free wans.

[dablik]

No mention of the bore size of the MC that i can see, assuming yours is currently OEM it has a 14mm bore along with those Blue spots, changing the MC with a different bore size which change the feel of how your brakes feel..

 

I'm sure other kwakers perches will fit.

[leehenty]

Take lever out, bore out the eye the minimum amount to round, press in a brass bush with top hat washer made to fit bore and height of gap. Make sure the washer bit is at bottom.
I had to do this to the Royal Enfield levers from new, as they flapped up and down like castanettes at idle, driving me nuts. No flapping now. You will need to find a model makeror someone with access to a metal lathe.

[fixitsan]

Take lever out, bore out the eye the minimum amount to round, press in a brass bush with top hat washer made to fit bore and height of gap. Make sure the washer bit is at bottom.
I had to do this to the Royal Enfield levers from new, as they flapped up and down like castanettes at idle, driving me nuts. No flapping now. You will need to find a model makeror someone with access to a metal lathe.

 

Look no further than the for sale section, where Madmoped racer has one for sale !