A broken clutch lever is a tell-tale sign of a dropped motorcycle.
A motorcycle's control levers are extremely sensitive to outside forces and often tell the tale of an embarrassing accidental drop. Aside from marring an otherwise pristine appearance of a Harley-Davidson Softail Deuce, a broken clutch lever can affect the performance of the machine. With a smaller area to grasp the lever, the rider may encounter difficulty when pulling in the lever, causing the clutch to only partially disengage and creating the risk of premature wear. Luckily, replacing the clutch lever is a quick task that can be done in a matter of minutes with only a few tools.
Instructions
1. Locate the cable adjuster at the midpoint of the clutch cable and push the rubber dust boots away from the adjuster. Loosen the adjuster's lock nut with your wrench. Twist the adjuster clockwise to loosen the clutch cable.
2. Remove the small screw and anti-rattle clip from the base of the clutch lever with your Phillips screwdriver. Pull the brass ferrule out of the clutch lever to release the lever from the clutch cable.
3. Remove the snap ring from the bottom of the clutch lever's pivot bolt with a pair of needle-nose pliers. Push the pivot bolt up and out of the clutch lever and the clutch lever perch.
4. Pull the clutch lever out of the clutch lever perch. Slide the clutch cable out of the notch cut into the clutch lever.
5. Insert the brass ferrule into the cable's catch loop. Slide the clutch cable into the new clutch lever's notch, and press the ferrule into the catch on the bottom of the clutch lever. Secure the cable into place, using a Phillips screwdriver to insert the small crew and anti-rattle clip into the base of the clutch lever.
6. Slip the clutch lever into the clutch perch. Insert the pivot pin through the top of the clutch perch and the lever. Push the snap ring onto the groove cut into the bottom of the pivot bolt.
7. Twist the cable adjuster counterclockwise to tighten the clutch cable. Use a wrench to tighten the lock nut against the cable adjuster. Pull the rubber dust boot over the cable adjuster.
Tags: clutch lever, clutch cable, cable adjuster, into clutch, pivot bolt, anti-rattle clip, base clutch