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super frustrated...clutch lever replacement..HELP! :)

4.1K views 18 replies 9 participants last post by  RJ2112  
#1 ·
Ok... So I'm FAIRLY mechanically minded. LOL But this is just the oddest thing.

I got a set of gorgeous Mad Scientist Moto levers. Brake went on like a breeze, like they do.

So I get into the clutch. First problem, I can't get the darn thing off. it won't come out of the housing. So I look and look, and it seems that I have to remove the electrical housing. Huh...interesting. But that pops right off and VIOLA, the clutch lever comes out. Problem solved. So I put on the new lever. Wham, bam, thank you ma'am.

But wait. It's AWFULLY loosy goosy. What the heck? OH!!! BUSHING! Duh.

So I take it all apart again... And first, while we're at this lull in the story... do you have to have ELF HANDS to work for Kawasaki? My GOD are the spaces to get to fasteners small.

Anyway... I pull the thing apart again. I pull the bushing from the stock lever. I put the bushing into the MSM lever. I go to put the lever into the clutch lever housing. And it won't go in. Just won't go in. It's like the bushing is too tall. But the bushing JUST CAME OUT. How can it be too tall for a space it JUST CAME OUT OF? That doesn't make any sense.

So I pull the bushing by itself out of the lever, and for the LIFE OF ME, I cannot make that bushing slide into the clutch lever housing. It's like it's a fraction of a millimeter too tall.

WHAT am I missing? Is there some little screw somewhere that you loosen to get the housing in, that you tighten after its in? It slid right out. But it will NOT slide back in. There's no burring. It's a brand new bike.
 
#2 ·
I had zero issues replacing my levers on a 2013 ZX6R,I used ebay levers then as Mad Scientist Moto was not making them at the time. I saw insan3guy with his levers from Mad Scientist Moto recently and damn, are those levers sexy. However,they take just minutes to install. The bushing or pin you are referring to just slides in and out. I don't get it. Why it is giving you difficulty. Pictures may help me understand. Sorry trying to run it through my head how to help you.
 
#3 ·
Hmm...that doesn't make much sense indeed. Should just go back in as long as it's aligned properly in the lever. My issue was putting the damn clutch cable in the new lever. Guess the trick was to align the slit from the adjustment knob with the slit in the housing (or whatever that's called) so you can slide out the cable and have a bit more room. Took me way too long to figure that out though lol
 
#7 ·
You installed the new lever without the bushing

you tightened the pivot bolt

you crushed the top and bottom together when your tightened it more trying to not have the "slop" (SPECULATION)

Now you can't get it together with the bushing

Does this about sum up the problem?


spread those fuckers back apart the mm or two you crushed it
 
#8 ·
I didn't "crush" it, but I did snug it... you very well may have the answer. Thanks! That makes sense, totally. :) I didn't notice the slop until it was together, and I didn't tighten it MORE, because the slop wasn't top to bottom, it was side to side. Super apparent immediately that it was the bushing. But yeah, what you say very well could be it.
 
#11 ·
Looks like I am a little late to the game but Riverz nailed it. Spread it back apart a bit and it should go right in like butta!
 
#19 ·
All you really need is a solid surface, with a gap slightly wider than the bushing that you can lay your lever on. Gravity will aid you with the process, instead of having to try and juggle everything while trying to get the force needed where it needs to be.