Clutch Lever install mishap

[Speeddog]

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.

[tonkoshala]

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...

[tonkoshala]

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!  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...

[tonkoshala]

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.

[minnesotamonster]

Another victim to the stupid set screw.  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.

[tonkoshala]

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...