Bending Aluminum Clutch Lever??

[TomK]

I have a GMA clutch lever, and would like to increase the “throw” to pull the clutch cable farther. It’s not pulling the cable far enough to completely release the clutch (Baker 6-in-4).

Here’s a picture of my clutch lever. It’s polished aluminum. I’ve 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 1/4” more travel for the clutch cable, which should be enough.



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

Thanks!

[JBinNC]

Get two. You will probably break the first one.

Jim

[Tattooo]

Get two. You will probably break the first one.

Jim

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

[TomK]

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

[flatman]

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.

[frisco1rigid]

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.

[selectedgrub]

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.

[TomK]

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.

[Tattooo]

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.....^^^^^^^^^^^

[TomK]

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.

[TomK]

Here are the before and after photos:



As you can see, I’m 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 couldn’t before.

I can’t test ride it right now, though, so I’ll have to wait to report on that.

[TomK]

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

[frisco1rigid]

Bravo !!
Excellent results.

[Hubbard]

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

[tzienlee]

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