Clutch lever mod

[maxcruiser]

I seen a thread in here about this mod but no explination on how to do it. I found this step by step proceedure on how to do it on a thread from vmaxchat forum. thought some of you maybe interested. The following is the thread as posted;


This modification is to ease lever pull, increase smoothness and stop wear in lever and pivot bolt

Parts required
1- clutch lever
1- Pivot bolt (clutch)
1- Bearing INA # HK 0810
1- 12mm drill bit
Locktite # 609 or # 680, stud and bearing retaining compound

Step 1
Drill hole in clutch lever with 12mm drill bit, be sure it?s straight.

Step 2
Slightly chamfer drilled hole to assist in installing bearing.

Step 3
Put a small drop of Locktite on out surface of bearing.

Step 4
Press carefully bearing into lever, press in till flush with lever.

Step 5
Have hardened sleeve made as per diagram. Use inside diameter of bearing as a guide to fit of sleeve, it should just slide in without force.

Step 5
Have Machinist turn down stock bolt as per diagram, so sleeve slides over modified bolt

Step 6
Use Locktite on inside of sleeve and press onto bolt. Allow time to set.

Step 7
Lube bearing and bolt with waterproof grease and reassemble clutch lever to master cylinder.

Step 8
Go try it out and feel the difference, no up and down lever play and very smooth and controllable lever pull.

 

[jimvette999]

I'd like to do this mod but where do I get a hardened sleeve made? :hmmm:

 

[maxcruiser]

I'd like to do this mod but where do I get a hardened sleeve made? :hmmm:

Any machine shop s/b able to help you out

 

[jimvette999]

Thanks for the write-up and parts list. Great mod IMHO. :cheers:


I've already replaced lever, tried a thin washer. Still sloppy.

Jim

 

[maxcruiser]

Thanks for the write-up and parts list. Great mod IMHO. :cheers:


I've already replaced lever, tried a thin washer. Still sloppy.

Jim

I can't take the credit for it - I took from another forum - posted because there was some threads here asking how to do it. IT does work great though.

Mike

 

[Thevmaxrider]

Wish I would have known about that before I bought my Nissin ZX14 clutch master..........

 

[Heretic]

Some of us rednecks in mid-america do not have machine shop connections. Someone needs to make these en masse and sell them to the rest of us losers. Any takers?

 

[hubeerjw]

I'm on it!

Jeff

 

[Dreamster66]

I'm on it!

Jeff

when you get em done....price please!

 

[maleko89]

Ditto Jeff! There's a beer or 12 in it for ya. :biglaugh:

 

[Dreamster66]

anything yet or is it too soon....

 

[joelyons50023]

i had a huge problem with this and I had an old mechanic friend of mine show me a pretty cool trick. instead of messing with bearings and a lot of searching for stuff just get a set of feeler gauges and find the one that fits pretty snugly above the lever, mine was .016'' take that one off and make a circle out of a chunk you cut off and drill a hole a little bigger than the bolt in the middle. mine has worked great for 7 months or so hopes this helps someone out that did not want to go through the hassle of the regular mod.

 

[maleko89]

So basically you made a washer out of a feeler gauge? Good idea!

 

[joelyons50023]

Thank you i too had tried to use various washers and grind them down but with no luck.

 

[hubeerjw]

Thanks for reminding me of this.... hopefully this fall I'll be able to get some things done!!!

 

[hubeerjw]

I definately don't always understand ya, but thats what makes it fun and frustrating all at the same time!!!

 

[dannymax]

I am not trying out for the Mr. Personality contest.:cheers:

Oh Great, NOW I find this out!!
I sent my ballot in less than 6 hours ago!! :bang head::bang head::bang head:

 

[lankeeyankee]

Oh Great, NOW I find this out!!
I sent my ballot in less than 6 hours ago!! :bang head::bang head::bang head:

Well like Naughty G says Lankee knows everything and is the greatest if you dont do it his way its wrong, Should have asked me who to get levers from..:rofl_200:

 

[naughtyG]

ooaaar do i detect a little sarcasm here from our lovely lankee? Hang on I haven't told ya how to drag race yet it's obvious you need a buncha lessons m8 lol

 

[hubeerjw]

Getting back on topic, I took some measurements on the stock bolt and the sleeve diameter is 7.9mm the ID of the bearing is 8mm. Instead of machining down the bolt and making a collar, I'm going to just drill out the lever to fit the bearing and then put the bearing over the stock bolt. I'll see how much slop I have and see if the collar is really necessary.