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Old 03-09-2013, 05:54 PM   #1
Jayrod1318 OP
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Wallered out Aluminum levers

Is there an easy way to shim or fix aluminum levers that have been 'wallered out"

My clutch lever pivot hole is quite loose....
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Old 03-09-2013, 06:10 PM   #2
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Yes, find a bushing with the correct I.D.
Drill the lever out to the O.D.
Install the bushing in the lever, reinstall on bike
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Old 03-09-2013, 06:27 PM   #3
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Can you just do it for me? Jeesh.

Are plastic ones like teflon ok? or just go with alum?
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Old 03-09-2013, 06:32 PM   #4
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Yes, plastic is Ok to use. Delrin would be a good choice. Teflon is OK but a little soft for the load of the operating the clutch.

Harley uses a plastic pin through an eye on the cable at the lever end of their set up. The plastic looks like UHMWPE.
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Old 03-09-2013, 06:40 PM   #5
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Originally Posted by Jayrod1318 View Post
Can you just do it for me? Jeesh.

Are plastic ones like teflon ok? or just go with alum?
If you send me the lever and the bolt I could put a bearing in it.
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Old 03-09-2013, 07:05 PM   #6
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Originally Posted by fritzcoinc View Post
Yes, plastic is Ok to use. Delrin would be a good choice. Teflon is OK but a little soft for the load of the operating the clutch.

Harley uses a plastic pin through an eye on the cable at the lever end of their set up. The plastic looks like UHMWPE.
ultra high molecular weight poly-ethylene ?
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Old 03-09-2013, 07:07 PM   #7
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If you send me the lever and the bolt I could put a bearing in it.
Getting the hole just the right size would be a trick, but even then it could be staked or epoxied in......

I see an Ace hardware trip in my future.
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Old 03-09-2013, 07:12 PM   #8
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When mine wear out, I ream them up and make aluminum-nickel-bronze bushings for them. I think its time for a hardened stainless pivot pin for the V-Strom front brake lever.
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Old 03-09-2013, 08:40 PM   #9
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Holy crap...a new clutch lever is what, 15 bucks?
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Old 03-10-2013, 01:21 AM   #10
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Holy crap...a new clutch lever is what, 15 bucks?
Yeah, that's what I was thinking. I replace my levers with new ones every few years. They feel like brand new.

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Old 03-10-2013, 08:00 AM   #11
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Vintage bike levers can be unobtanium-I'm currently looking for a nice 1972 Honda CL100 lever and the OEM was bent so no bushing fix. "Wallered out" equals oldish?
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Old 03-10-2013, 08:20 AM   #12
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Replace, and periodically remove and re-lube with a nice molydenum disulfide grease. Levers work like buttah, for just about evah.
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Old 03-10-2013, 08:39 AM   #13
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^ What Bob said. Hiya, Bob!

Plus what others have said... it will be less expense if you consider your time to just replace them and then keep 'em lubed.
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Old 03-10-2013, 10:11 AM   #14
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Originally Posted by kantuckid View Post
Vintage bike levers can be unobtanium-I'm currently looking for a nice 1972 Honda CL100 lever and the OEM was bent so no bushing fix. "Wallered out" equals oldish?

Technical term for hole that has been enlarged from wear.

good thing this ain't JM
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Old 03-10-2013, 10:16 AM   #15
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I dug into the perch assembly last night and discovered part of the problem is the bolt that was used on the pivot is incorrect. Should be a shoulder bolt of some kind... not just a regular bolt. the levers have bushings in them that appear to be in ok shape.

My clutch and decomp lever are on the same pivot, so its little tricky.
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