Sorry guys, but I've got a noob question to ask. I dumped my 510 and bent the clutch lever. On the back side there appears to be a notch where it bent, I don't know if it came that way or if it formed upon bending. 1. I figure I have one stress reversal cycle before it breaks. What's the best way to straighten it without breaking it? 2. How does the clutch lever operate the starter interlock? I see only two screws attaching it, the screw to the clutch master cylinder, and the pivot screw. Where's the interlock located?
the notch is purpose built to allow the the lever to snap off at the dimple point, to prevent complete lever failure in a race/ride (its a racing derived mod). fixing is a very touchy thing, usually the euro levers (magura/Brembo) are better at bending back. Ive used the box end of a wrench, a pipe, and have even put them in a vice and tapped them with a hammer (anyone else have a trick) the clutch lever perch has a 2 wire switch that is circuit closed when the lever is pulled. if you dont like this sw its easy to remove and the pigtail wires terminate into male/ fem bullet connectors, so you pull the switch disconnect the wire ends and simply plug the bike wire harness male /fem bullets together and no more interlock switch.
You did not mention the year but, call Up-tite in Santa Ana and get the levers he sales/makes. No more bendy-brakey.
I've bent mine many times before and sometimes the bend feels good in my hand so I just leave it It you happen to snap it, just get a file and round off the end ... There is a slight safety issue here as the lever can always stick inside you after a fall easier than if it has that ball shape on the end of it ....
I actually like my clutch lever like that. Easy to get my hand on and off it quicker and less to get in the way.
If you first anneal the area to be bent the lever won't break. If you have an acetylene torch, get a dirty flame going and put a layer of soot on the area to be bent. Then adjust the torch for a soft clean flame and slowly heat the area until the soot burns off. After the soot burns, the piece is heated to about 800 degrees F and is annealed and bending is possible with out breaking. If you have the correct temp. stick, it can also be used to get to the right temperature and a map torch can be used. Just be sure to heat slowly, because overheating will damage the lever. The temper will return to the lever afterwards, on it's own.
