slug Posted May 27, 2006 Share Posted May 27, 2006 Meant to post this a month or two ago... Was giving the bike a pre-springtime lookover and noticed the clutch lever was getting sloppy, as in lots of up and down play. Pulled the lever off and the whole pivot area was dry as a bone. Looked at the pivot hole on the lever and it has become very, very oval. Looked at the pivot pin, very, very not round. I don't think that the pivots were ever greased at the factory (and shame on me for not checking sooner.) To make a long story short, this is another place to check for "intermittent" greasing from the factory. I was able to get rid of some of the play by lining the pivot hole on the lever with super-thin brass shim stock (.001" - .003") and rotating the pivot pin 180 degrees when reinstalling the lever. Of course, a generous helping of waterproof grease has been applied. Hope this helps... Link to comment Share on other sites More sharing options...
Guest ratchethack Posted May 27, 2006 Share Posted May 27, 2006 Good reminder, Slug. It's yet another dry-from-the-factory place for lube. I use boat trailer wheel bearing grease about every 10K miles. My dirt bikes have always suffered from ovalling of the lever eyes due to vibration. I like your shim idea, but it takes a LOT of wear to get 'em that far out..... I have a stack of shim washers that I use for this on the dirt bikes, stacking them between lever and lever housing, but I like your idea - seems like a really good alternative. FWIW - for those yet to be initiated, the pesky little ball-bearing and "Puck-like" gizmo's that actuate the clutch and brake switches and their springs like to dive for the deepest, darkest corners of y'er shop when you take the levers off!! Link to comment Share on other sites More sharing options...
slug Posted May 27, 2006 Author Share Posted May 27, 2006 FWIW - for those yet to be initiated, the pesky little ball-bearing and "Puck-like" gizmo's that actuate the clutch and brake switches and their springs like to dive for the deepest, darkest corners of y'er shop when you take the levers off!! 90439[/snapback] Amen, Brother. In fact, doing my repair, one of these little bastards took off somewhere, never to return. Made a replacement out of a thick nylon screw with the threads shaved off. Link to comment Share on other sites More sharing options...
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