Fixing a broken lever

[rcgreg]

Drat - It's Friday night and your bike has just kicked itself off the kick stand and fallen on it's side. Worse than that - the Clutch/Brake lever has snapped in half. Even worse than that there is no chance of getting a replacement for days - and the big ride is tomorrow 8AM sharp. Well fear not, here's a way to repair that lever so that you can ride while you wait for a new part to arrive.

To do this you will need

a) A rotary tool - such as a dremel tool with a cut off wheel.
b) JB Weld or similar product
c) a piece of wire about 1 1/2 inches long and 1/8 thick - cut a piece off a nail if you like.
d) Both pieces of the broken lever
e) Electrical tape
f) Thin CA glue

Step 1. Remove the lever from the bike and using that stretchy black electrical tape wrap it end to end so you can see the break and the tension on the tape hold the pieces in alignment.

Step 2. Using the tin CA - drip some of the glue onto the break so that it wicks in between the pieces.

Step 3. Go have coffee or polish the exhaust pipes - giving at least half an hour for the glue to thoroughly dry.
No - the glue is not going to hold the pieces together in service - it's only purpose is to hold the pieces in alignment while you do step 4.

Step 4. Using the dremel cut a slot on the back side of the lever that is centered on the break and runs about 3/4 of an inch past the break in either direction.
It needs to be thick enough so the piece of wire (Nail) will fit into the slot. Make it about half as deep as the thickness of the lever.

Step 5. Mix up some JB Weld and coat the slot in it, pressing the piece of nail into the slot so that it acts as a joiner for the two pieces.

Step 6. LET IT DRY ! Make sure you follow the directions to allow the JB to cure - usually a couple of hours.

Step 7. Using sand paper clean off the excess dried JB Material and re-install the lever.

Your Good to GO !

You should of course consider this a temporary fix at best - and replace the broken lever when the new part arrives. But this will get you going for the short term.

Keep the rubber side up !

[virgilmobile]

Good temp repair.I do carry JB Weld in the bike emergency kit on the week long trips.Back-strapping with steel for the touque is great.
Did you get pictures for us who need a visual aid?

[rcgreg]

Alas - I did not take pictures. I should have I know, especially as I am so very visually challenged. I hope the description explains it well enough for you - if not let me know and I will try to explain in more detail. The best thing of course - is no never encounter a situation where you need to do it! Except to help out a friend !

[rcgreg]

OK - you've shamed me into it - here are some pics

[rcgreg]

Now we wrap the two pieces with electrical tape - so that we can still see the break and then dribble some CA into that break and let it dry.

Tape goes end to tend

[rcgreg]

Note the long black line that is centered on the break, I have cut a slot into the lever, and placed a piece of music wire - or a piece of a nail into the slot and filled it with JB Weld.

Note the black area

[rcgreg]

All you need to cut the slot is a Dremel or similar tool with a cut off wheel

[WingAdmin]

Great idea! Just for those who are wondering: CA = cyanoacrylate glue, aka "crazy glue" or "super glue".

[rcgreg]

I knew that - but I couldn't spell it

[CharlaineC]

would it not be a goo idea to keep an old set of clutch/break leavers in your emergency kit. for this reason.
Also is there a good list of what should be carried for an emergency kit?

[rcgreg]

Yes - by all means keep a spare ! There are other lists of what to carry in an emergency kit, besides better tools than Honda supplies, you need something to repair a leaky coolant hose, fuses, wire, duct tape, spark plug, electrical connectors, an electrical crimper, and most of all - some cash!!!