Gen1 Clutch Lever Maintenance?

FJRBluesman · Jun 12, 2010

I just ran into this one today...

I had a bunch of gift certificates to Cycle Gear and just bought a set of Pazzo levers. I got the front brake on real quick then moved to the clutch side.

I removed the stock clutch lever and the little brass bushing fell out of the lever. This brass bushing has a small hole in it, about half way or so thru the cylinder, so the clutch master cylinder plunger can go into it and push when the lever is actuated. I picked up the bushing and noticed it was, 1) Very worn. 2) Oval shaped. 3) The hole was nearly clean thru the bushing. Note the blue circled area has a small hole in it where it's worn thru. Also note the lips, ridges, etc, and beat appearance. BTW - I have about 53K on the bike.

I've heard many people complain about the clutch letting off to close to the grip, etc. It may be possible that this bushing is so worn that it doesn't give full motion of the lever. I had no issue with this as I took care of it by installing my SS clutch line just after I bought the bike. This may really change things up when I get the new bushing.

So for now I have a Pazzo front brake lever and stocker clutch lever. I did clean and lube everything while I was in there too. The part should be in by Tuesday next week. You may want to look at your just for grins.

The brass bushing I'm referring to is number 4 (3GM-26455-00). It costs $6.47.

Dark triangle area is thru hole from other side.

Bustanut joker · Jun 12, 2010

FWIW.. I lost me clutch bushing twice in my old shop before I got decent lighting..

I must admit that hunk of **** you have displayed above looks like ya might have tossed a handful of sand at a freshly greased part before re-assembly..

Yer startin' to sound like a nood ratballs

FJRBluesman · Jun 12, 2010

Bustanut joker said:
FWIW.. I lost me clutch bushing twice in my old shop before I got decent lighting..I must admit that hunk of **** you have displayed above looks like ya might have tossed a handful of sand at a freshly greased part before re-assembly..

Yer startin' to sound like a nood ratballs

I love you too Barry. :wub: :friends: :wub:

beemerdons · Jun 12, 2010

FJRBluesman said:
Bustanut joker said:

FWIW.. I lost me clutch bushing twice in my old shop before I got decent lighting..I must admit that hunk of **** you have displayed above looks like ya might have tossed a handful of sand at a freshly greased part before re-assembly..

Yer startin' to sound like a nood ratballs

Click to expand...

I love you too Barry. :wub: :friends: :wub:

Bluesy, Bust is right; you're indeed a nood ratball. But this was a very timely and informative technical tidbit. I'm preflighting Miss Lucy Liu before CFR 2010 in Quebec, I'll definitely check this bushing.

Bustanut joker · Jun 12, 2010

beemerdons said:
FJRBluesman said:

Bustanut joker said:

FWIW.. I lost me clutch bushing twice in my old shop before I got decent lighting..I must admit that hunk of **** you have displayed above looks like ya might have tossed a handful of sand at a freshly greased part before re-assembly..

Yer startin' to sound like a nood ratballs

Click to expand...

I love you too Barry. :wub: :friends: :wub:

Click to expand...

Bluesy, Bust is right; you're indeed a nood ratball. But this was a very timely and informative technical tidbit. I'm preflighting Miss Lucy Liu before CFR 2010 in Quebec, I'll definitely check this bushing.

I've two extras in like new condition if ya need one Don.. If yer real nice I'd bring one along

:jester:

Bustanut joker · Jun 12, 2010

FJRBluesman said:
Bustanut joker said:

FWIW.. I lost me clutch bushing twice in my old shop before I got decent lighting..I must admit that hunk of **** you have displayed above looks like ya might have tossed a handful of sand at a freshly greased part before re-assembly..

Yer startin' to sound like a nood ratballs

Click to expand...

I love you too Barry. :wub: :friends: :wub:

So what are you doing tonight luv?

:jester:

RadioHowie · Jun 12, 2010

Ain't nuthin' sadder'n a aging queen. :sadsmiley02:

beemerdons · Jun 13, 2010

RadioHowie said:
Ain't nuthin' sadder'n a aging queen. :sadsmiley02:

That's classic RH, I had to look twice to tell if I was looking at Fairlaner or Mum!

Harald · Jun 14, 2010

Coincidentally, I just had mine apart for semi-annual lubing and noticed the same wear although the hole isn't worn through yet. My bikes a 07 with 37k on it. So it sounds like even regular maintenance won't stop the requirement for an occasional bushing replacement.

Neil San Diego · Mar 4, 2011

I recently noticed that the bushing on my clutch lever had excessive movement as well, so I got a relacement bushing for it. Just replaced it last night - a total of 5 minutes including cleaning everything. The old bushing was in even worse shape than FJRBluesman's. It had a hole completely thru it.

I noticed a HUGE difference on my commute into work this morning. Apparently that worn out bushing wasn't allowing the clutch to completely disengage. Now it's back to smooth shifting. Probably the biggest bang for the buck of anything I've done to my feejer.

Thanks Simon! I owe you a drink of your choice next time I see you.

SacramentoMike · Mar 4, 2011

beemerdons said:
QUOTE (FJRBluesman @ Jun 12 2010, 02:49 PM) QUOTE (Bustanut joker @ Jun 12 2010, 02:47 PM) FWIW.. I lost me clutch bushing twice in my old shop before I got decent lighting..

I must admit that hunk of **** you have displayed above looks like ya might have tossed a handful of sand at a freshly greased part before re-assembly..

Yer startin' to sound like a nood ratballsI love you too Barry.

Bluesy, Bust is right; you're indeed a nood ratball. But this was a very timely and informative technical tidbit. I'm preflighting Miss Lucy Liu before CFR 2010 in Quebec, I'll definitely check this bushing.

Simon, think it's time to change your "Member Title" from "Mr. FJR Gumby" to "Mr. Nood Ratball."

Just a thought.

dcarver · Mar 4, 2011

Ahh crap now I have to look too.

FJRBluesman · Mar 20, 2011

Neil San Diego said:
Thanks Simon! I owe you a drink of your choice next time I see you.

DEAL!

SacramentoMike said:
Simon, think it's time to change your "Member Title" from "Mr. FJR Gumby" to "Mr. Nood Ratball."

Just a thought.

Great idea, thanks Mike! I like your member title Mike. :rofl: How is Charlie these days? :huh:

dcarver said:
Ahh crap now I have to look too.

Ha ha! Made ya looook!

gumba · Mar 20, 2011

Can't imagine how crappie your clutch must have felt with a barrel that looked like that. Can't think of a maintenance chore that costs less and pays bigger dividends. You can go into this completely brain dead and come out with a stiff thump er. There is nothing like a smooth clutch. Incidentally an oil can will not do the job. Complete dis assembly and a good grease is the ticket.

Bustanut joker · Mar 20, 2011

:haha:

Damn! I forgot all aboot Nood Ratballs :headbonk:

beemerdons · Mar 21, 2011

Bustanut joker said:
:haha:

Damn! I forgot all aboot Nood Ratballs :headbonk:

I'd forgotten RadioHowie posted up a pic of Fairlaner!

FJRMGM · Mar 23, 2011

all this jabber got me concerned about how mine might be worn.

Pleased to report that at 80,000 miles mine looks nearly as good as new on my '05 FJR.

But then again, I lubed mine every 5-10k miles.

Canadian FJR · Mar 23, 2011

I also took things apart for a little look see and cleaning and all is well. The return of the clutch lever does seem a little slow. The lever should spring back a little quicker once released, any suggestions on the cause. I wonder if a good flush and bleed would correct this?

Canadian FJR

Fred W · Mar 23, 2011

Maybe it's because it's still sub zero up there?

Maybe just wait till it gets warm enough out for the grease to melt down a little...

Gen1 Clutch Lever Maintenance?

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