Clutch lever modification.
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Thread: Clutch lever modification.

  1. #1
    Junior Member paultreid's Avatar
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    Clutch lever modification.

    The clutch lever assembly on my 78 CB400TII is damaged; the lever it’s self is fine, but the Metal in the lower hinge is broken, so the lever moves up and down. I bought generic lever assemblies, since piston in master brake cylinder was also bad, which works great in right side, but as you will know, on left side, the clutch lever is built into the left side controls. What I was wondering, is if anyone has attempted to cut the lever assembly off the controls and then use a separate clutch lever assembly? I am worried that if I cut the metal between controls and clutch lever, the controls section may get damaged (cavity in metal between both sides?). Thoughts?

  2. #2
    Senior Member Alan F.'s Avatar
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    I'm not sure if there's a cavity in there or not but I'll be doing just that on some upcoming projects.
    paultreid likes this.
    "That awkward moment when you end up using advice from an ichiban moto video"
    CB250 Nighthawk projects 92,93,92.
    81 CM400C Sold
    93 CB750 Nighthawk Sold
    73 CB750K3 Long term project stuck in the 'parts collecting stage.'
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  3. #3
    Member pitzky's Avatar
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    I seriously doubt there's a cavity, it would be a weak spot for the clutch lever holder and might break off, plus it would be harder to manufacture. I think you should simply split it open and look at the part that has the lever holder. If the inside edge is smooth all the way there's no way there would be a "pocket" inside, and you can just grind the clutch lever away and then simply paint (if needed) the exposed part. I guess those are made of cheap aluminium so corrosion shouldn't be a problem, just aesthetics
    paultreid likes this.
    partially restored functioning 1979/1980 CM400T (VIN too consumed to be properly read)

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  5. #4
    Junior Member paultreid's Avatar
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    Cut the lever assembly off with a grinder, very easy. Filed the rough edges down, quick coat of paint, looks awesome. The after market clutch lever just slips right in as if it was designed to fit that way.

  6. #5
    Senior Member Alan F.'s Avatar
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    Pics for the vicarious?
    "That awkward moment when you end up using advice from an ichiban moto video"
    CB250 Nighthawk projects 92,93,92.
    81 CM400C Sold
    93 CB750 Nighthawk Sold
    73 CB750K3 Long term project stuck in the 'parts collecting stage.'
    Fork Swap info: http://sites.google.com/site/alansdocuments/

  7. #6
    Senior Member oupa's Avatar
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    No experience with your particular model but I have cut down perches several times. Paul pretty well summed it up.

    I would suggest careful inspection of the damaged part though. I'm assuming this damage came from some mishap. Make sure the collar doesn't have any cracks that will weaken it when loosened/tightened! Your clutch lever falling off while riding can be quite an experience! Don't ask how I know this.

    EDIT - BTW, Please be careful if you ARE using a grinder! Aluminum is nasty stuff. Hard on grinding wheels and you!
    "They're not like cars with a body that rusts out in a few years. Keep them tuned and overhauled and they'll last as long as you do. Probably longer." - Robert Pirsig

  8. #7
    Junior Member paultreid's Avatar
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    Photos.

    Attachment 295872
    Attached Thumbnails Attached Thumbnails Clutch lever modification.-8f328f50-a7a9-49bb-a3d1-08a03ff2969b.jpg   Clutch lever modification.-c4e06b0c-4f8a-4c69-a2bc-1fac88ce36c0.jpg   Clutch lever modification.-522909c7-b0fb-4687-9d9b-de8f40a4738d.jpg  

  9. #8
    Super Moderator longdistancerider's Avatar
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    Very nice
    Jim O'Brien
    1979 CM400T "road bike" modified for travelling
    1978 CB400T1 restored
    1972 CL350 nuts and bolts restore in progress


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