Clutch lever bits on the 1200

Today, some part of my clutch lever decided to "break"....

I assumed it was the cable snapping, but when I got home to read the manual.... oh, no cable...

So what has happened is this metal bit that I am trying to picture either fell out and / or snapped, about where the ends of the cable would go if there was one, at the clutch lever.

I was lucky enough not to drop the bit at 100kmh, and stuff it in my pocket.

It's time's like this that the whole can't start the bike without the clutch being pulled in is REALLY BLOODY STUPID.....

So, two questions... does anyone have experience pulling the clutch lever assembly apart on the 1200 (06) and is it particularly difficult?

Two, how does one remove the clutch lever kill switch?

Thanks.

Hi Stu

Looks like the plunger has managed to drop out, should be easy enough to unbolt the lever & pop it back in. Round end of rod goes into to activate clutch & the small round barrel locates into the lever (if nothing is broken that is)

Hope this helps, just checked my 2006, barrel drops in from the top of the lever

Pops

Pops wrote:Hi Stu

Looks like the plunger has managed to drop out, should be easy enough to unbolt the lever & pop it back in. Round end of rod goes into to activate clutch & the small round barrel locates into the lever (if nothing is broken that is)

Hope this helps, just checked my 2006, barrel drops in from the top of the lever

Pops

Thanks for that...

hoping that it hasn't snapped.... the end isn't symmetrical, not sure if it was before... Any ideas? The bit of the metal facing the camera on the left....

I was overtaking a big bloody truck at the time it happened, very exciting.

Give me a few minutes & I will take my clutch lever off & check how many parts you should have, back soon.

Pops

Pops wrote:Give me a few minutes & I will take my clutch lever off & check how many parts you should have, back soon.

Pops

thanks, mate.

Maybe you can do mine as well

My folks are in Perth... bike's kinda a long way away from there though

stu wrote:

Pops wrote:Give me a few minutes & I will take my clutch lever off & check how many parts you should have, back soon.

Pops

thanks, mate.

Maybe you can do mine as well

My folks are in Perth... bike's kinda a long way away from there though

Ok, all the bits look right apart from the locating barrel (the short round bit that the rod is located into) mine appears to be made of brass, I think, & the hole doesn't go right thru on mine but that shouldn't matter because it really just locates the pin into the lever. If the lever isn't off yet unbolt from the bottom then unscrew the bolt, take the lever off insert the round end of the plunger into the hole under the clutch housing the short barrel into the vertical hole in the lever, locate the other end of the rod into it, lever replaced & bolt in etc. The way your photo is displayed is how it should look when located in the lever you just need to place the other end into the actuator. Oh & a bit of grease on the moving bits helps but you might what to do a trial run putting it together first. Good luck

Pops

Thanks pops.
That's a great help.
I was worried it was going to be a drama.

A picture here could be worth a thousand words I'd expect

stu wrote:

It's time's like this that the whole can't start the bike without the clutch being pulled in is REALLY BLOODY STUPID.....

Not that I have the 1200 but I do take a spare set of Hong Kong levers on trips ($18 the set) just in case.

Is that delivered and fitted?

Just some cheap eBay specials from Hong Kong.  But a roadside fitting is simple on the 1250 as both clutch and brake are hydraulic so there is not cable attachments.

Ewok1958 wrote:Just some cheap eBay specials from Hong Kong.  But a roadside fitting is simple on the 1250 as both clutch and brake are hydraulic so there is not cable attachments.

Haha sorry I misread your post, and thought you were trying to sell it to me


Good idea, though.


I'm looking again at the bit that fell out, and thinking that it is indeed worn and that I therefore need a replacement part.

Where to start looking (other than expensive motorcycle shop)?

Anyone ever used this website for parts?

Are they any better / cheaper than anywhere else

http://trevorjordanmotorcycles.com.au/oemonline/suzuki_search.php

Couldn't find an 06 photo but here is the 01-05 fisch from Alpha Sports , I'm pretty sure it will be the same, the Push Rod is part no 59871-38A00 (part 4 on the drawing) and the Bush is 59892-08A00 (part 5):



The US price is only $6.34, so I'd say Suzuki Aust would be pretty close to the same - that is if they stock parts that old.  Wreckers would probably not seperate the rod, you might need to buy a complete Clutch Master Cylinder plus handle then take the gamble its not as worn as yours.

Good luck.  

stu wrote:Anyone ever used this website for parts?

Are they any better / cheaper than anywhere else

http://trevorjordanmotorcycles.com.au/oemonline/suzuki_search.php

Using the part numbers from Alpha the rod is $5.42 and the bush $4.72 from Trevor Jordan, probably the cheapest component you'll ever need to replace

barry_mcki wrote:

stu wrote:Anyone ever used this website for parts?

Are they any better / cheaper than anywhere else

http://trevorjordanmotorcycles.com.au/oemonline/suzuki_search.php

Using the part numbers from Alpha the rod is $5.42 and the bush $4.72 from Trevor Jordan, probably the cheapest component you'll ever need to replace

Thanks, yep got the pair for $10 and 14 cents
Pick up from local store tomorrow, delivery online was gonna be $15....

It's the same part for up to 2010, which makes it simple.