Faces of Death: Clutch Lever Bolt

[indywar360]

Someone has been using a hand saw to cut a bolt off my bike. Who would use such a crude tool so recklessly? Look at all the missing paint and the exposed metal. This is a travesty.

They also attempted to "pound" the bolt downward by brute force. They did this for many, many hours, increasing the amount of intended force using various tools that were not suitable for the job. They used an interchangeable screwdriver as a punch and chisel, a crescent wrench as a hammer, a punch as a punch, and a ratchet wrench as a larger, heavier hammer. None of these methods were successful.

After this they went back to the hardware store and bought an electric drill. They drilled downward through the bolt, breaking a drill bit off inside the bolt, but eventually penetrating the entire thing by drilling through the bottom as well.

See, it's hollow, but you can't see through it because of the drill bit.





What is left is a soulless, used up metal sock puppet totally shamed and unrecognizable from its original form, but which still refused to come out and even more incredibly, still functioned as a clutch lever bolt on multiple rides they took to the hardware store, grocery store, on the freeway to work, home, etc. This is incredibly dangerous and not something that would be recommended by Suzuki mechanics.





Later this person realized the sock puppet would not move because its shaft is TWICE AS THICK on the upper portion, TO PREVENT IT FROM FALLING OUT. Thus it rests on the lower wall of the clutch perch and CANNOT BE POUNDED OUT. THE NUT HAS TO BE REMOVED FIRST, NO MATTER WHAT.

Now I have to buy a goddamn new clutch perch along with a new clutch lever! This work is just not up to my standards of how to go about doing things, I have decided to do things myself from now on and not let anyone else go near my bike. 

[scratch]

What do you mean, "someone"?

Either, "someone" was trying to steal your lever...

...or, trying to 'seize' your clutch lever, so you couldn't ride away.

Where was your bike, when this happened?

[natedawg120]

Yeah man,  what the deuce?  I can see a couple of scenarios.  First is that someone was going to take you lever, like stated above.  They were trying to make the lever fall of while you were riding/starting the bike, maybe they hate motorcyclists :dunno:, OR some douchebag just wanted to vandalize something, OR some mechanic is a moron and should be shot ...

[wever411]

I thought he was trying to say that "someone" was himself and he did the hack job. Maybe that's why he had the smiley face at the end of his post?

[scratch]

Yes, why would someone push down to remove a bolt when the head, which is obviously larger, wont fit through?

[indywar360]

Because they are stupid and didn't even look carefully at the replacement clutch lever bolt that they already had in its brand new package... they failed to understand the basic fact of the clutch lever bolt.

[Blu_Spd_Dmon]

Thats a pretty radical "clutch adjustment" 
Maybe a chain saw would work better 

[coll0412]

Since said "someone" wants to learn the hard way, I would try and repair the clutch perch if the hole is not to f-ed up

By some paint stripper at a local autoparts store, especially the stuff they say is for air-craft finishes, it will cause the old paint to fall of quicker than a prom dress. Then you can be totally pimped out and polish it, or buy some good quality primer and some flat black and repaint it, noting the fact you will have to sand out those...gouges.

[The Buddha]

I think its time to say it ...
"Stupid Indywar" said the GS.
He is to be thrown into the same cage as that ManchesterGS.
Amazing. Pot metal lever and bracket, and you didn't break any of it. Stupid, but amazing.
Cool.
Srinath.

[indywar360]

I ordered a new one already as the mounting bracket has been widened enough to disengage the clutch switch occasionally. Couldn't really clamp it closed much.

And I did break my cheapass $5.99 replacement lever when I tried to put it into the perch and it wouldn't fit. So I tried to pry the perch open with the lever and... it broke. But it was crap anyway... last time I order some weirdo part off Ebay.

So the moral of the story is:

cut off the nut first should this ever happen again. Probably a dremel tool would be worth buying.

[Blu_Spd_Dmon]

Why were you cutting the bolt off in the first place? striped?

[yamahonkawazuki]

stripped?, no wrench? lol been there someone

[indywar360]

stripped to the max.  I had been working on that thing for 2 weeks.

Since I probably tend to undertighten rather than overtighten, I suspect this is due to the crash, when the clutch lever hit the ground it bent, widened the perch, which probably pulled the nut and bolt with a lot of force, wiping out the threads. In any case the part is well designed considering it didn't come off.

[Blu_Spd_Dmon]

did you get the insurance worked out with that B****? I remember you saying her insurance said it wasn't her fault  or that you should split it?

[Foreverunstopable]

lol...

I guess now its to late you get you the gs500 manual you wanted...

"If anything in life requires either force or money you should re-evaluate your plan of attack."

[indywar360]

I already have the Clymer manual. This was was the OEM factory-trained procedure as outlined. 

re insurance, the appraiser came by and called it totaled, he was actually pretty cool and helpful.

Sentry Insurance sucks nuts. At the 8-week mark the adjuster hadn't even called me and then was wanting me to split liability 50/50, but she hadn't even taken statements from either of us. "The holidays and all..."   Smack. So, not sure what the final outcome will be.

When I told the insolent wench I had had injuries to my nads and johnson she seemed to come around a little, and later mumbled about an injury settlement offer they would make.

I talked to an attorney but I'm going to wait for their offer first--the lawyer basically just negotiates for you and take 33-40% off the top. It rarely ever goes to court. So maybe I can do it myself in the spirit of GSTwins... if it's enough money to move to LA then it'll be a "blessing in disguise" as the preachers say.