QuestionI recently purchased a 1980 Honda CB650 that was sitting in a garage for 20 years not being ridden except once or twice a year. It has approximately 8000 miles on it. It has a broken clutch lever on it I would like to replace myself, unfortunately I'm no mechanic. I tried to remove the screw holding the lever to the handle bars but it wouldn't turn and I don't want to strip it. I'm not sure if there is a special sequence I should use for removal of the old lever or if the threaded screw is just rusted into place and needs some lubricant for removal. Is there anything I should know about the connection of the new lever before it is installed? Lubrication of clutch cable etc. Can you help me on this one?
Thank you
AnswerHi Rod,
You need to invest in a service manual. I recommed you spend the additional cash and buy Honda's Service Manual. Clymer and Haynes are l;ess expensive, but we get what we pay for, so to speak.
The manual has all the procedures to repair and maintain your MC. It will pay for itself with the first repair or maintenance you perform.
Use AllExperts when you have the manual and need assistance.
Clutch lever:
1) Loosen the clutch cable adjuster lock wheel and rotate the adjuster in towards the lever.
2) Align the slots in the adjuster and lock wheel.
3) Align those slots with the slot on the clutch lever assy.
4) Pull the clutch lever in and hold.
5) Grab the the cable firmly just behind the adjuster and pull while releasing the lever.
6) Slack in the cable should allow you to pull the cable thru the slots. If necessary, increase slack via lower clutch cable adjuster and repeat above step.
7) Remove cable lead bead (and bushing if applicable) from lever.
8) Remove the nut from the bottom of the lever screw.
9) Remove the screw.
10) Remove the lever from the assy.
11) Insatllation is reverse.
12) Adjust cable free play.
Respectfully,
Mark Shively
