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Is your clutch/brake lever too floppy?

Started by FJmonkey, August 03, 2013, 12:38:42 PM

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FJmonkey

August 03, 2013, 12:38:42 PM
Like us our bikes are all getting older, things getting looser, center stand sagging, clutch lever flopping around... You know the drill. I took my clutch lever off today to understand why it was so damn loose. There is not much material on the lever for the shoulder bolt to contact. The hole is slowly getting larger from use. I could drill it and press a bushing in. But that still does not fix the lack of mating surfaces. So I decided to shim it top and bottom to take up the free play from a different direction. First, punch out some shims from a beverage can like this.



Then install like this. Top and bottom.



Now my lever feels snug and proper, no more flopping around. Next, the center stand spring....
The glass is not half full, it was engineered with a 2X safety factor.

'86 Ambulance - Bent frame, cracked case, due for an overhaul
'89 Stormy Blue - Suits my Dark Side

fintip

#1
August 03, 2013, 12:45:13 PM
Huh, is that really the source of the vertical freeplay on the levers? Mine has so much that it's incredible to imagine that it's purely due to wear on the hole there. I always thought some shim was already missing or something. I mean, it must have an inch or more at the tip of up and down motion available to it. Buzzes something silly at just the right RPM...
fjowners.wikidot.com

Not everyone understands what a completely rational process this maintenance of a motorcycle is. They think it's some kind of a knack or some kind of affinity for machines in operation. They are right, but the knack is almost purely a process of reason.
-ZAMM

IBA:54952

FJmonkey

#2
August 03, 2013, 12:55:31 PM
Yep, mine seemed as bad as yours, now at the tip it is more like 3/8" free play. Not that the free play hurt anything or was a safety issue, just feels better having it tightened back up.
The glass is not half full, it was engineered with a 2X safety factor.

'86 Ambulance - Bent frame, cracked case, due for an overhaul
'89 Stormy Blue - Suits my Dark Side

Travis398

#3
August 03, 2013, 12:59:41 PM
I love any Mod that requires me to drink a Beverage before I start................  :drinks:

Time to work on my levers I guess......


When all you have is a hammer, everything looks like a nail.

rktmanfj

#4
August 03, 2013, 01:00:03 PM

But that would require going out and buying canned beverages...   :bad:

Randy T
Indy

Blessed be the LORD my strength, which teacheth my hands to war, and my fingers to fight.
Psalms 144:1

'89 FJ1200
'90 FJ1200
'78 XT500
'88 XT350

FJmonkey

#5
August 03, 2013, 01:05:39 PM
Quote from: not a lib on August 03, 2013, 01:00:03 PM

But that would require going out and buying canned beverages...   :bad:



Randy, you make a very good point. Now what upgrade can I do on the FJ that requires glass?
The glass is not half full, it was engineered with a 2X safety factor.

'86 Ambulance - Bent frame, cracked case, due for an overhaul
'89 Stormy Blue - Suits my Dark Side

ribbert

#6
August 03, 2013, 09:39:05 PM
Clutch and brake levers respond VERY well to a dismantle, clean and grease. They are very exposed and get a lot of crap in them. There is also a lot of drag if dry. If done regularly, almost eliminates wear.
Noel
"Tell a wise man something he doesn't know and he'll thank you, tell a fool something he doesn't know and he'll abuse you"

ken65

#7
August 03, 2013, 10:36:52 PM
good idea

FJ_Hooligan

#8
August 03, 2013, 11:26:51 PM
Quote from: FJmonkey on August 03, 2013, 01:05:39 PM
Quote from: not a lib on August 03, 2013, 01:00:03 PM

But that would require going out and buying canned beverages...   :bad:



Randy, you make a very good point. Now what upgrade can I do on the FJ that requires glass?

Simple, stamp the shims from the bottle cap.
DavidR.

fintip

#9
August 04, 2013, 01:46:23 PM
Quote from: FJ_Hooligan on August 03, 2013, 11:26:51 PM
Quote from: FJmonkey on August 03, 2013, 01:05:39 PM
Quote from: not a lib on August 03, 2013, 01:00:03 PM

But that would require going out and buying canned beverages...   :bad:



Randy, you make a very good point. Now what upgrade can I do on the FJ that requires glass?

Simple, stamp the shims from the bottle cap.

^Nailed it.
fjowners.wikidot.com

Not everyone understands what a completely rational process this maintenance of a motorcycle is. They think it's some kind of a knack or some kind of affinity for machines in operation. They are right, but the knack is almost purely a process of reason.
-ZAMM

IBA:54952

Pat Conlon

#10
August 04, 2013, 02:42:40 PM
Tough crowd here, eh Mark? This forum has been know to eat it's young... Just ask Mike.
1) Free Owners Manual download: https://tinyurl.com/fmsz7hk9
2) Don't store your FJ with E10 fuel https://tinyurl.com/3cjrfct5
3) Replace your old stock rubber brake lines.
4) Important items for the '84-87 FJ's:
Safety wire: https://tinyurl.com/99zp8ufh
Fuel line: https://tinyurl.com/bdff9bf3

FJmonkey

#11
August 04, 2013, 06:18:04 PM
Quote from: Pat Conlon on August 04, 2013, 02:42:40 PM
Tough crowd here, eh Mark? This forum has been know to eat it's young... Just ask Mike.

Yea, I with ya on that Pat, good thing I am not one of the young anymore.... And I can survive, even missing a few chunks...
The glass is not half full, it was engineered with a 2X safety factor.

'86 Ambulance - Bent frame, cracked case, due for an overhaul
'89 Stormy Blue - Suits my Dark Side

ken65

#12
August 04, 2013, 10:00:02 PM
hey fj monkey, i see that plastic thing with holes in it that appears to be a guide, what do you call it and where do you get them from, ?when i try to make my own gaskets, rubber washers etc at least half the time the centre hole isn't right in the middle after i use my punch,
ken

FJmonkey

#13
August 04, 2013, 10:17:08 PM
Quote from: ken65 on August 04, 2013, 10:00:02 PM
hey fj monkey, i see that plastic thing with holes in it that appears to be a guide, what do you call it and where do you get them from, ?when i try to make my own gaskets, rubber washers etc at least half the time the centre hole isn't right in the middle after i use my punch,
ken
Ah... A gadget man, I will post a pic to help you along. I pulled it out of the trash at my work about 10 years ago. Took me 3 seconds to understand what I had. Not bad for dumpster diving... First time I have used it.
The glass is not half full, it was engineered with a 2X safety factor.

'86 Ambulance - Bent frame, cracked case, due for an overhaul
'89 Stormy Blue - Suits my Dark Side

craigo

#14
August 04, 2013, 10:48:07 PM
Quote from: FJmonkey on August 03, 2013, 12:38:42 PM

Now my lever feels snug and proper, no more flopping around. Next, the center stand spring....

Hey Mark, what you got for the center stand? Mine drags going around corners due to lack of spring tension. Is your "fix" going to cure that or is your stand just loose?

I fixed my sidestand using a magnet. I just used a self tapping screw and drilled it into the footpeg bracket. Sidestand snug as ever. I have 4 more of these magnets if you want one... However, I still am trying to use one of them to keep the center stand in place.


CraigO
CraigO
90FJ1200
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