FITTING A NEW CLUTCH LEVER

1

I mean, really – how is this supposed to work? The cable line is miles out. ‘Buy cheap and pay dear’ as they say – this internet-sourced pattern lever is not going to work without some attention... 2

The problem is the pivot bolt hole is in totally the wrong place; luckily there’s space to move it to where it should be, so I marked the spot and dot punched it. 3

But the catch is, if I drill the hole in the position I’ve marked, it will overlap the existing hole, leaving a figure of eight that will quickly wear through. 4

So I need to plug the original hole first. I could try brazing or silver soldering it up, but it’s probably easiest just to tap the hole out – a ¼in BSF tap worked fine. 5

I had a bit of ¼in diameter brass bar in my metal stocks, so I cut a BSF thread onto that with a die to make a plug I can screw into my threaded hole. 6

I probably could have used locking compound but as both parts are brass I soldered it in place to make it as much as possible one-piece with the lever bracket. 7

Then I cut off the excess and filed it smooth before setting the bracket up in the pillar drill to drill the new hole, beginning with a pilot hole from a centre drill. 8

You can see the difference here; if I had tortured the cable into the lever as supplied (right) the bend on the cable would soon have caused fraying and breakage.