Sticky Clutch Lever - Wrist Twisters
 
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post #1 of 13 Old 09-14-2008, 07:05 AM Thread Starter
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Sticky Clutch Lever

Alright, here's the deal. I got on it pretty good the other day and it felt like the clutch slipped. As the front started to get light, the bike revved a little too quick for the amount of acceleration. I started looking for adjustment issues but did not find any.

What I did find was that the clutch lever does not appear to release fully on it's own. It feels a little stiff. To start, I was going to remove the bolt/nut that holds it on and clean it up. I removed the nut from the bottom and the problem went away, but the bolt with the screw head on it appears to be stuck to the lever. I can't get it apart but am wondering what I need to do to remedy my problem. I would like to think I can just drive the bolt out (assuming it is not threaded into the lever), but don't know. Does all that make sense?

HELP!

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post #2 of 13 Old 09-14-2008, 07:15 AM
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It's threaded.
Unscrew it.

Lube it up after cleaning the lever & pin.
Put it back in snug.
Hold it in position, & tighten the nut. don't forget the thread lock.

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post #3 of 13 Old 09-14-2008, 07:16 AM Thread Starter
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Addition

Forgot to add....

I have looked at the diagram here... http://www.bikebandit.com/houseofmot...m2015sch306458 ... and cannot tell if it is only threaded into the nut or if it threads into something else.

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post #4 of 13 Old 09-14-2008, 07:18 AM Thread Starter
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Quote:
Originally Posted by xrmikey View Post
It's threaded.
Unscrew it.
I tried but it won't turn. I tried using an appropriate sized flat head screw driver on top but it just moves the lever. The most I have gotten it to turn is about 1/8th turn then it locks. Tried working it back and forth to get the crud out but it didn't do anything.

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post #5 of 13 Old 09-14-2008, 07:21 AM
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It's threaded into the lower part of the perch, only.
Use some penetrating lube & keep at it. It will come.

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post #6 of 13 Old 09-14-2008, 07:25 AM
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Impact driver,not the air type.A must have if you work on your on bikes.



Got a stuck bolt/screw...do what feels right smack it with a hammer.(using the impact driver ofcourse)

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post #7 of 13 Old 09-14-2008, 07:26 AM
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The lever should have plenty of room between the lever & pin.
It is just binding on the bushing inside the lever.
Let the lever twist up against the grip(zip tie it if you have to)& keep spraying lube & turning the screw.
It's a PITA when this kind of thing happens.

You might have to get a pair of pliers on it.

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post #8 of 13 Old 09-14-2008, 07:30 AM
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post #9 of 13 Old 09-14-2008, 07:35 AM Thread Starter
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I had thought about the hosing it with WD40 but didn't know if it would damage the switch inside. I'll tie it back and hose her down after church. It's really crappy weather today so I'll have all kinds of time to work on it. As long as it's done by the ride on the 20th I'm good.

Thanks,

Chris

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post #10 of 13 Old 09-14-2008, 07:37 AM Thread Starter
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I'll go by sears and see if I can add this, or something similar, to my toolbox.

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post #11 of 13 Old 01-23-2009, 11:24 AM
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I got the same problem as cmurphy84, a stuck clutch bolt. Been soaking it with a break free type of solution for two days now and it just won't budge. Haven't tried impact driver yet as I don't have one but will soon. In the mean time does anyone have any other suggestion?


-smitty

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post #12 of 13 Old 01-26-2009, 08:07 PM
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Well the impact driver is not working for me, it is bending my clutch lever and not turning the bolt. I think I'm going to have to buy a new perch, bolt and maybe lever switch. Great.

So, does anyone know if the switch(#8) is removable? Anyone have any clutch perch/bolt laying around that they would like to sell? Or, would it be best to just order perch #13, bolt #19, and switch #8?

http://www.bikebandit.com/houseofmot...-2005/o/m15631


-smitty

Never Under Any Circumstance Take A Laxative And A Sleeping Pill On The Same Night.

1985 Suzuki GS550-sold
1988 Kawasaki ZX10-R.I.P.
1989 Honda CBR600-sold
2000 Honda CR250R
2005 Honda 919
2006 Bandit LX250
2008 Kawasaki KLR650-sold
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post #13 of 13 Old 01-26-2009, 08:15 PM
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my suggestion would be to get the best quality..(klein, snap on, etc) screwdriver bit you can afford and then use it carefully with a ratchet with the proper attachment to let you use the bit... with a bit of luck it will come loose... but if the impact you tried didnt work i think you should try a different brand of penetrating oil and possibley ask for divine intervention..



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