Ducati Monster Forum

Moto Board => Tech => Topic started by: tonkoshala on July 06, 2009, 06:02:52 PM

Title: Clutch Lever install mishap
Post by: tonkoshala on July 06, 2009, 06:02:52 PM
I was installing my crg levers today and ran into a problem. They did not come with the part that is needed for the clutch to engage. I went to remove the one from the stockers and it snapped in half. Tried to look up the part, but haven't had any luck....


Anyone know the part number or an alternative?
Title: Re: Clutch Lever install mishap
Post by: tonkoshala on July 06, 2009, 09:12:39 PM
Just found out it's called the lever perch...any ideas where I can pick one up?

NO clutch perch means no ride for me  [bang]
Title: Re: Clutch Lever install mishap
Post by: chixstrip on July 06, 2009, 10:28:24 PM
I don't think you can buy that part separately. Might need to buy a new stock lever just to get that part, else get it off someone's wrecked monster
Title: Re: Clutch Lever install mishap
Post by: DarkStaR on July 07, 2009, 06:53:40 AM
Find someone who bought AVS levers, and buy their old stuff.

ASV levers come with one with their levers.
Title: Re: Clutch Lever install mishap
Post by: tonkoshala on July 07, 2009, 07:44:25 AM
Talked to Ducati today and you actually have to buy the entire master cylinder. $200

Thanks for the tip darkstar. I posted in the parts wanted section, but I'm gonna start looking around now.
Title: Re: Clutch Lever install mishap
Post by: Speeddog on July 07, 2009, 08:23:35 AM
Do you mean the little pushrod and barrel assembly?

Can you post a pic of the broken part?
Title: Re: Clutch Lever install mishap
Post by: tonkoshala on July 07, 2009, 08:52:28 AM
(http://i96.photobucket.com/albums/l184/tonkoshala/Perch.jpg)

Title: Re: Clutch Lever install mishap
Post by: Speeddog on July 07, 2009, 09:04:51 AM
IIRC, in the past Ducati Seattle had replacements for those.

There's a *tiny* set screw in the barrel that locks the threaded pushrod in place.
Pick away as much of the loctite from the setscrew as you can, make sure the allen key fits well, apply some heat, and spin the setscrew out.
Pick away the loctite from the threaded part, make sure the allen key fits well, apply some heat, and spin it out.

Replace the threaded part with DucSea unit or make a copy from an M6 bolt.
Title: Re: Clutch Lever install mishap
Post by: tonkoshala on July 07, 2009, 09:18:15 AM
Quote from: Speeddog on July 07, 2009, 09:04:51 AM
IIRC, in the past Ducati Seattle had replacements for those.

There's a *tiny* set screw in the barrel that locks the threaded pushrod in place.
Pick away as much of the loctite from the setscrew as you can, make sure the allen key fits well, apply some heat, and spin the setscrew out.
Pick away the loctite from the threaded part, make sure the allen key fits well, apply some heat, and spin it out.

Replace the threaded part with DucSea unit or make a copy from an M6 bolt.


Yeah I missed the tiny screw...Called Ducait Seattle same news from them...well a little better. You have to buy the lever for 119. Crossing fingers on someone having a spare laying around. Does anyone happen to know if it's 12mm or 8mm? I am just a fella who is completely self taught on all my garage knowhow. Trail and a LOT of error [cheeky]
Title: Re: Clutch Lever install mishap
Post by: Speeddog on July 07, 2009, 09:24:50 AM


Quote from: tonkoshala on July 07, 2009, 09:18:15 AM
~
12mm or 8mm?
~

???

Which part?
Title: Re: Clutch Lever install mishap
Post by: DarkStaR on July 07, 2009, 09:27:52 AM
Try and visit a couple of local dealers.  Their parts shop might just have what you're looking for laying around. 

It amazes me what they have just sitting there sometimes.
Title: Re: Clutch Lever install mishap
Post by: tonkoshala on July 07, 2009, 09:49:00 AM
Quote from: Speeddog on July 07, 2009, 09:24:50 AM

???

Which part?


The barrel...I got a PM from someone asking saying they might have what I need.

I've called several dealers and get the same response. I'm in Memphis TN and the closest Duc dealer to me is in Little Rock or Nashville.
Title: Re: Clutch Lever install mishap
Post by: He Man on July 07, 2009, 10:13:28 AM
you know... it looks a lot like you can just die cast one at home or even modify one of those furniture mounts (no idea what they are called ,but you know what im talking about if you've ever put together a cheap closet or a shelf or cabinet). thats the alternative to actually buying one. OR you can go on the DML and PM Motored Sports. he usually carries a lot of odds and ends.
Title: Re: Clutch Lever install mishap
Post by: Speeddog on July 07, 2009, 11:11:37 AM
Quote from: tonkoshala on July 07, 2009, 09:49:00 AM

The barrel...I got a PM from someone asking saying they might have what I need.

I've called several dealers and get the same response. I'm in Memphis TN and the closest Duc dealer to me is in Little Rock or Nashville.

I can't measure one right now, but my guess is that they're 10mm diameter.

Your (looks broken) pushrod has an M6x1.0 thread, as does the barrel.
Title: Re: Clutch Lever install mishap
Post by: tonkoshala on July 07, 2009, 11:18:54 AM
Quote from: Speeddog on July 07, 2009, 11:11:37 AM
I can't measure one right now, but my guess is that they're 10mm diameter.

Your (looks broken) pushrod has an M6x1.0 thread, as does the barrel.

If I can get the stub out of the barrel you think a dremel down a M6 bolt would work?
Title: Re: Clutch Lever install mishap
Post by: Speeddog on July 07, 2009, 11:44:29 AM
You need to taper it down, and round off the end, just like your broken pushrod.
Could be done with a dremel, not the easiest way, but it depends on your toolbox.
Title: Re: Clutch Lever install mishap
Post by: tonkoshala on July 07, 2009, 05:44:33 PM
Pretty limited. What would be the best method? My dremel runs off an air ratchet set. I have no standard vice so I thought I'd use a set of long nose channel locks to hold the bolt while I dremel it down.

First I have to get the old pin out. The thing is in there tight. Maybe a few mins in the over will help persuade the lil bastard to come out...
Title: Re: Clutch Lever install mishap
Post by: tonkoshala on July 07, 2009, 07:46:43 PM
Didn't really toss it in the oven, but heated it up...no luck the little damn hex screw is in there and not coming out!  [bang] So much for that idea...tempted to sell these levers and go to ASVs. They were my first choice anyhow, but got a deal on the CRGs.

Now I did find a fella willing to sell a new stock lever for $70. I think with all the time it's going to take to fab one of these up I'd rather just spend the money...
Title: Re: Clutch Lever install mishap
Post by: tonkoshala on July 08, 2009, 10:35:03 AM
Broke down and bought a new lever for $70 this AM. Too impatient to wait around any longer. Someone should really start stocking this part.
Title: Re: Clutch Lever install mishap
Post by: minnesotamonster on December 03, 2009, 04:56:39 PM
Another victim to the stupid set screw.  [bang] Didn't notice it until it was too late, but I still can't get the damn thing out.  Same problem as the op, except I snapped it completely off. Anybody have that part laying around who upgraded to asvs?


Thanks.
Title: Re: Clutch Lever install mishap
Post by: tonkoshala on December 03, 2009, 05:25:54 PM
i ended up ordering a new clutch level assembly. Got a great deal on it from a fella who distributes Brembo to most the shops in the US. Lemme know if you don't have any luck I do still have his number. It was more than half price than what I could find anywhere else...