Another of Fred’s cunning fixes

The wife and I went out on our A65 on Monday, and all the time my clutch lever was bouncing up and down. I usually put my index finger on it to stop it. So, when I got home, I decided to do my little repair.

When I make an HT lead, I sometimes have to cut the brass terminal down so I always save the brass cut-off. First of all, I remove the lever and clean out the hole on the handlebar part of the lever. After cleaning, I measure and cut the brass to the correct thickness and take a slot out of it to enable it to fit into the hole. Then I press the brass into place with a pair of gas pliers (you can put a spot of superglue in). Ordinary pliers will do but gas pliers work best. Then I try a new Allen stud in the hole (sorry to say it’s a stainless metric one!). If it doesn’t fit I dress it with a needle file. When happy I reassemble using good grease and make sure that I don’t overtighten everything. Works a treat. It’s no use putting the original screws back in as they are usually too worn.

For the A65 I actually turned down an old brass bolt to make the insert (couldn’t find the offcuts from the HT leads at the time). I’ve done this to a few of my motorcycles.

Fred and Jean Austin