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  1. #1
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    Default Bending Aluminum Clutch Lever??

    I have a GMA clutch lever, and would like to increase the ďthrowĒ to pull the clutch cable farther. Itís not pulling the cable far enough to completely release the clutch (Baker 6-in-4).

    Hereís a picture of my clutch lever. Itís polished aluminum. Iíve watched videos of people using a propane torch to heat clutch/brake levers while applying leverage (pipe, wrench, etc) to bend them. As you can see in the picture, if I hear the circled spot, I could bend the lever out to the point where it would be parallel to the grip. This would give me maybe 1/4Ē more travel for the clutch cable, which should be enough.

    Click image for larger version. 

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    Is this advisable? Would the lever weaken or crack? Has anyone done anything like this?

    Thanks!

  2. #2

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    Get two. You will probably break the first one.

    Jim

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    Quote Originally Posted by JBinNC View Post
    Get two. You will probably break the first one.

    Jim
    Yep he might need to get 3 just to be safe..................

  4. #4
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    I hope not. I already had to modify it to work with a Shovelhead clutch cable.

  5. #5

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    I remember reading somewhere you can bend aluminum but only one way. Bending it back will break it. Tried it on a couple of bent aluminum fins, one with heat and yeah they both broke. But again I was bending them back straight.

  6. #6

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    I have done it a few times. I do Not use heat because Aluminum does Not show signs of softening or bendability, it just falls apart.
    These two handles are the old style 4-speed on a Mousetrap, I have no idea if the metal is diff on the New style handles.

    I was very careful and slow.
    It seems to me that taking up some "slack" in the cable might be a solution.

    Click image for larger version. 

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  7. #7

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    Put the cable end in a vice and a ring spanner over the ball end.
    Wave a OA torch over the full length as you apply slight pressure on the spanner.
    You will soon feel it move, slow and a gradual heat is what you do.
    Move the spanner up the lever to even out.

    This is a bicycle crank which I made into a mirror stem.


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    Thanks. I’ll give it a try tomorrow. I guess if I break it I can use the clutch lever off my Ironhead while I get another.

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    Quote Originally Posted by selectedgrub View Post
    Put the cable end in a vice and a ring spanner over the ball end.
    Wave a OA torch over the full length as you apply slight pressure on the spanner.
    You will soon feel it move, slow and a gradual heat is what you do.
    Move the spanner up the lever to even out.

    This is a bicycle crank which I made into a mirror stem.
    ^^^^^ He should know more than anyone here.....^^^^^^^^^^^

  10. #10
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    I was able to bend it this morning using the technique selectedgrub recommended. Once it cools down, I’ll post before and after photos. Thanks again.

  11. #11
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    Here are the before and after photos:

    Click image for larger version. 

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    As you can see, Iím able to pull the lever in farther now. I think this may have fixed my problem. Now, when I pull the clutch lever in all the way, I can spin the clutch hub with my hand. I couldnít before.

    I canít test ride it right now, though, so Iíll have to wait to report on that.

  12. #12
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    Tested it in my driveway. No pulling in first gear with the clutch pulled in.

  13. #13

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    Bravo !!
    Excellent results.

  14. #14
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    Quote Originally Posted by selectedgrub View Post
    Put the cable end in a vice and a ring spanner over the ball end.
    Wave a OA torch over the full length as you apply slight pressure on the spanner.
    You will soon feel it move, slow and a gradual heat is what you do.
    Move the spanner up the lever to even out.

    This is a bicycle crank which I made into a mirror stem.

    the difference between a man thats done it and a bunch that ain't

  15. #15
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    they bend real easy when ya bike falls over or leans against a wall but a bastard to straighten out after !!

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