Join Date: Aug 2009
Location: The Knobs, Kentucky
Mentioned: 0 Post(s)
Broke mine, too. How I fixed 'em.
I dropped my bike and broke the clutch lever, too. I noticed that the remaining lever was about as long as the two-finger race levers I had seen, and I thought I might be able to approach the look.
The lever broke in the weakened area, so I took the broken piece and cut the ball off of the end with a hacksaw; ground the cut end down to approximately the roundness of the ball. Then I used a grinder to shape and taper the end of the lever until it would fit in the factory recess of the ball. Using QuikSteel Epoxy, I attached the ball to the end of the broken lever, shaped it to taper properly, and left it to harden for 24 hours.
Then I removed the lever and applied three coats of Plasti-Dip tool handle coating to smooth out and cover my 'cut and epoxy' roughness. Reinstalled the lever, liked the working feel and looks, so I did the front brake lever, too.
In the pictures, you will notice that the levers are not the same length on the finished work; but they both end at the same location on the grip, and feel the same when gripped.
"It is the journey, in the end."