broken cluch lever :( - Kawasaki Versys Forum
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post #1 of 22 (permalink) Old 07-27-2009, 09:17 AM Thread Starter
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broken cluch lever :(

'08 Versys -

Well, my new pretty Versys is no longer unscarred. The kickstand failed me - not to mention my own carelessness - and the bike fell on the kickstand side the cowling is scratched a little and and little cracked - no big deal - the only real damage is a broken in half clutch lever (still useable).

Do I need to buy just a new lever, or a whole "lever assembly"?
Is this a difficult repair? any pointers for DIY?

I checked over all the systems, felt the handle bars still tight with the wheel, and did a 20 mile ride with no apparent problems. Any concerns I should be looking for on the bike now that it was dropped?

Many thanks!
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post #2 of 22 (permalink) Old 07-27-2009, 09:20 AM
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My V dropped on the same side, however I was nearly run off the road. Same thing here, clutch lever was bent and half snapped off after I tried to ...re-bend...it. It is only like $10 to buy a new OEM lever, and with the shop manual, it is a fairly simple 10-15 min replace at most. Good luck!
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post #3 of 22 (permalink) Old 07-27-2009, 09:43 AM Thread Starter
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thx

shop manual - ah yes - thx!
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post #4 of 22 (permalink) Old 07-27-2009, 09:47 AM
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Bad luck struck me to on Saturday on my way home from a ride with dragonbreath and Deweybrian. I stopped to take a break tried to cut it to sharp into a parking space and dropped my v on the right side, I scuffed the bar end weight and broke the tip of the break lever no other damage done.
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post #5 of 22 (permalink) Old 07-27-2009, 10:13 AM
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I know this won't help your current situation but for future protection; I have always left my bikes in first gear when parked. After shutting the engine off, I roll the bike forward to take all the slack out of the drive train then set the bike over on the side stand. That way it can't roll off the stand.

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post #6 of 22 (permalink) Old 07-27-2009, 10:49 AM Thread Starter
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1st gear

Yes, that is a good idea -I was doing that when I first got the bike, then got lazy - that will teach me...........LOL
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post #7 of 22 (permalink) Old 07-27-2009, 10:53 AM
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in my moto cross racing days...good days....I would cut the clutch lever in half, then file down smooth for fast 2 finger shifting. works great. especially lining up for the tripple jumps!

if it were easy....everyone would do it!
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post #8 of 22 (permalink) Old 07-28-2009, 08:05 AM Thread Starter
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ah ha!

I knew there was a silver lining to this, thanks Jimmy! Alas, I could not find any triple jumps for my V on last night's ride!!
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post #9 of 22 (permalink) Old 08-29-2009, 08:13 PM
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It's easy to repair broken clutch and brake levers, and they're stronger than original. Drill a 1/8 hole about 1/2 inch deep down the center of the two pieces. Cut a steel pin about 7/8" long. I use old spring pins, but a thick coat hanger or anything similar will do. Sometimes you have to bend the pin a bit so that the tip lines up with the rest of the handle. Use JB Weld to glue the pin into the holes and to fill the gap. Next day, sand it down and paint the handle with aluminum paint. If you're careful, the repair is invisible. New handles are cheap, but repaired handles are cheaper, and stronger.
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post #10 of 22 (permalink) Old 08-29-2009, 11:18 PM
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Now I feel like I just wasted my money! This evening, I ordered new brake and clutch levers from cyclepartsnation.com (yes, my bike has been down on both its right and left sides and I am now sick of riding with bent/broken levers). Perhaps I should have just repaired them. Unfortunately, I have a bad association with JB Weld (it is a long story).
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post #11 of 22 (permalink) Old 08-30-2009, 07:57 AM
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You should put a center stand on it so you don't have those problems any more.

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post #12 of 22 (permalink) Old 08-30-2009, 11:59 AM
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Quote:
Originally Posted by dallasdon View Post
You should put a center stand on it so you don't have those problems any more.
The stand that failed when my bike fell was me in each case. Two (of the three) times that it fell over was after I had to perform a quick stop when someone pulled in front of me. The third time was when, at night, I put my foot down into a depression and couldn't stop the bike from leaning too far.

The Versys is my first bike and I have noticed that all of the incidents of me letting the bike fall over happened some time ago. I never replaced my levers figuring that I would just mess them up again. What do you know, but several months later I have not had the bike down again.

Thanks for the suggestion. I am thinking about the center stand, but I will most likely build one of those emergency stands out of PVC pipe that was described on this forum last year.
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post #13 of 22 (permalink) Old 08-30-2009, 01:34 PM
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lol...you gotta be kidding me. 2 days ago, I'm doing a little videoing of my doing simple wheelies. I'm cutting a u-turn in front of my house, my rear wheel gets into the dewey grass and bike falls right over. ARRGHGHGHGH! lol...felt like a total idiot. Popped the clutch lever in half and now have a quarter-size scrape on left fairing.

lol...read the opening post and felt like it was me typing parts of it!
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post #14 of 22 (permalink) Old 08-30-2009, 04:25 PM
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Quote:
Originally Posted by ovidgsd View Post
I knew there was a silver lining to this, thanks Jimmy! Alas, I could not find any triple jumps for my V on last night's ride!!
HELL - you COULDN'T have been trying!!!

Ed
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post #15 of 22 (permalink) Old 08-30-2009, 04:28 PM
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Quote:
Originally Posted by dallasdon View Post
You should put a center stand on it so you don't have those problems any more.
Wink, wink, - nudge, nudge!

Ed

PS Oh, BTW, a member here MAKES center stands. Can't remember who...?
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post #16 of 22 (permalink) Old 08-31-2009, 06:52 PM
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The 09 levers have weak spots cast into them so that only the end will usually break off, leaving enough lever to get home on. The earlier ones don't have this. I wound up just putting Barkbusters on mine, which will address the lever concern.

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post #17 of 22 (permalink) Old 09-01-2009, 07:11 AM Thread Starter
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I did wind up getting a PITBULL center stand - very nice!
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post #18 of 22 (permalink) Old 09-30-2009, 09:40 PM
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i actually fell in love with the half-clutch lever...i even trimmed another inch off so i could keep my ring/pinkie finger gripped while clutching with middle/pointer. Liked how it felt so much that I called my local Kawa dealer back and told him to cancel my order for replacement lever.
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post #19 of 22 (permalink) Old 10-01-2009, 12:16 PM
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Replacing lever only takes a couple minutes. Have done both without the shop manual. Just watch how it comes apart and away you go. I have actually kept both of my broken levers as spares incase I should manage to do worse damage at some point. They broke quite a distance from the pivot point and are still usable. I could not however find the broken off parts to try to fix them - darn! Maybe next time! (hope not)
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post #20 of 22 (permalink) Old 10-05-2009, 06:19 PM
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Best price for clutch levers is Kawasaki Parts Nation. Best price for brake levers is Rocky Mountain ATV and MC. They are only $20 and is the whole assembly just like OEM. RMATV-MC has clutch levers also, but they are black and cost the same as KPN.
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