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How to change clutch lever?

Started by rayshon, November 06, 2011, 11:38:00 AM

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rayshon

So as many of you probably know, I am pretty dumb when it comes to working on cars/bikes (which is why I'm here  :D). I need to replace the clutch lever on my GS because I fell last sunday and the lever is slightly bent so that the cable is about 2mm pulled in (which means occasional clutch slips at high rpms/lots of throttle).

I got the new lever, but I can't figure out how to get the old one out. My haynes manual says nothing on it (which is silly since levers always get damaged in falls), so I tried googling but it's pretty vague. I looked at it myself and saw that the first thing I should have taken out was the pivot bolt, but I can't get the bolt out. I tried wrenching it from the top but that did nothing but rotate the whole thing, and I can't get to the bottom nut because it is waaay too cramped to get a wrench in there. Wtf do I do?? ):


adidasguy

That will be one of my next videos.

Basically:

Best for bike on center stand and in neutral

1. REMOVE THE SWITCH!  If you don't, you'll break it off (See my brake lever video for why)
2. Loosen the clutch cable at the lever and the engine so you have some slack in the cable
3. Take nut and bolt off clutch lever
4. Like up the slot in clutch adjuster so you can slide cable out with the lever
5. Take cable off lever
6. Apply a little lithium grease to pivot hole and where cable goes
7. Good time to apply some lube to the clutch cable while it is free
8. Put cable on new lever and reverse the process to put it back in
9. Re-install the clutch safety switch - be sure it is the right way and that the tab goes into the hole in the lever. Test switch by seeing if bike starts when pulled in, and won't start when lever out.
9. Adjust clutch cable free play according to the manual or WIKI
10. Be sure everything is tight and slide the rubber boot over the clutch lever again.


the mole

I recently did mine, just as adidas said, but you have an 'F' model, so I guess its hard to get at the nut due to the fairing. If all else fails you might have to pull the fairing off?

rayshon

i hope I don't have to pull the fairing ):

also adidas where are your videos?

adidasguy

#4
Nope - that nuts is so easy to get at. I've replaced levers and even the top plate to put on OEM clip ons - never had to take off any of the fairing.

Only time I had to take any off was to install the R&G sliders because I had to drill a hole in the  fairing.

An alternate is:

* Loosen the cable first - both ends.
* You should be able to remove the cable from the lever
* Loosen the perch and rotate it to get at the switch and the nut
* Replace lever, put switch back on
* Rotate back
* Put cable back on
* Adjust clutch cable per specifications.

You can't rotate the perch with the cable on because the instruments can get in the way. Though you can rotate 10 degrees or so which is more than enough to easily get at the switch and the nut.

Be on the center stand so you can rotate the handle bars to get at the stuff easily. Often, you rotate handle bars RIGHT so what you need to get at for clutch stuff is over the open, inside part of the fairing.

Watch this video. I talk about clutch levers and SHOW the difference in them so you don't brake the clutch safety switch.
http://www.youtube.com/watch?v=BAWh85DXkfM


adidasguy

#5
If you can wait a day, I'll make a video tomorrow night.
Was going to do MosFet next, but can do clutch lever next. Got all assorted levers and perches out and on the demo table ready to go. E and F bikes in position.

PS: Just finished the opening credits. Pretty cool! I'll shoot the rest tomorrow and post it in the wee hours of the morning when I finish it.

ghostrider_23


HaydenH

#7
did this to my 06 F about a month ago. is straight forward once you work out a plan.
i undid the clutch switch (unplug first, and unscrew the housing)



plug is centre with the wires going in, the two screws are either side with little lock washers.
the nut is (quite literally) directly behind the plug in this view. just be gentle with the screws since the housing is plastic after all.

then you should have easy access to the bottom nut for the clutch lever.

- 2006 GS500F -

adidasguy

OK - Did it.
http://www.youtube.com/watch?v=1-yM57FL99U

Not totally happy with it - it was cold and late. Got a little wordy at times. Need to re-do it and tighten it up.
anyway, that's what happens when you do it all alone late at night.

rayshon

I DID IT!!!

I changed the lever!! It seems like nothing to you guys but as someone who isn't mechanically inclined I feel really accomplished..

Thanks guys (especially adidas for your video!!!!)

Biggest problem was removing the screws for the switch because those were small and somewhat stripped. I got them out and back in but let's just say I reaaally hope I don't have to take it out again anytime soon.  :D

I would try it out and see if it starts up right and the clutch feels right on the road but it's too late at night here so I'll do it tomorrow morning :)

adidasguy

Congratulations for your first session at wrenching on your bike!   :woohoo:

Glad the video helped.

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