Bending A Clutch Lever.

[GolfVenture]

What is the best way to unbend a MKII clutch lever. The bend is slight, but enough to notice a slight difference compared to when it was straight.

 

Maybe heat it up and sandwich the lever between two flat surfaces excluding the round ball at the end of the lever. Then use a couple of C clamps to press the lever straight?

[Prairiehammer]

Heating aluminum enough to make a difference while straightening it is problematic. It is not the same as steel. Most likely, when you heat it, it will either break when you try to straighten it or it will suddenly melt/sag. Either way, you will have to replace the lever.

I would just try to straighten it while cold by using gentle increasing mechanical forces (not by hammering). After all, the lever was cold when it was bent, right?

 

Having said that, just go get another lever. There are some on eBay (aftermarket and used OEM) for ~$9 and up.

[uncledj]

[eusa1]

straightened several this way:

 

remove lever from bike and put on concrete floor and hold loosely with the ball end touching floor and the slave end end touching the floor with high center pointing to the sky then take a heavy 22oz or better hammer and tap the high point in a light repeating manor until the lever has met the angle you desire.

 

don't rush the process and don't use a light hammer and a heavy hand

 

heavy hammer light hand tap tap tap and don't try it on wood or steel or bench of any size . concrete floor required.

 

no heat!!

[GolfVenture]

Thanks to all.

 

I will try the heavy hammer with a light hand. If that does not work then will order one.

[eusa1]

report back!

[MiCarl]

I've had to repeatedly straighten the clutch lever on my wife's Shadow. In her case, I do it with the lever mounted to the motorcycle.

 

I put a piece of pipe (actually, an old fork tube) over the end of the lever. Using my body and left hand I lever the pipe so it's torquing the lever to its original shape. Then I heat the bend with a PROPANE torch until it moves. Don't use excessive force!

 

Too little heat and it might snap. Too much and your lever may end up a puddle on the floor (although it takes a lot to get there with propane). By having the bending force on the lever as I heat it I'm sure to get enough heat without melting the lever.

[ricksbike]

I have done t the/same way as Micarl for years,as long as you maintain pressure while heating it works great..