If your motorcycle hand clutch lever is broken, you can follow these steps to fix it:
Gather the necessary tools and replacement parts: You'll need a set of wrenches, pliers, a new clutch lever (specific to your motorcycle model), and potentially a new clutch perch if it's damaged as well.
Disconnect the clutch cable: Locate the clutch cable where it connects to the broken lever. There is usually a barrel adjuster or a lock nut securing it in place. Loosen the lock nut, and then turn the adjuster to give slack to the cable. Once there is enough slack, disconnect the cable from the lever by sliding the barrel out of its holder or releasing any retaining clips.
Remove the broken lever: Locate the mounting bolt that secures the lever to the clutch perch. Use the appropriate wrench to remove the bolt and separate the broken lever from the perch. Be careful not to lose any small components or springs that may be attached.
Install the new clutch lever: Place the new clutch lever onto the perch and align it with the pivot hole. Insert the mounting bolt through the lever and perch, and tighten it securely using the wrench. Make sure the lever moves smoothly and freely.
Reconnect the clutch cable: Slide the barrel adjuster into the holder or engage any retaining clips, ensuring that the cable is properly seated. Adjust the clutch cable tension by turning the barrel adjuster or lock nut until you achieve the desired free play according to your motorcycle's specifications. Typically, you should aim for 1-2 mm of free play at the lever.
Test the clutch operation: With the new lever in place and the cable connected, check the clutch lever's movement and operation. Ensure that it engages and disengages the clutch smoothly without any binding or excessive play. Adjust the cable tension if necessary to achieve optimal clutch operation.
Check for proper clearance and alignment: Verify that the clutch lever doesn't interfere with any other controls, such as the brake lever or handguards. Ensure that it is properly aligned and positioned for comfortable operation.
Remember to consult your motorcycle's service manual for any specific instructions or torque specifications related to your clutch lever replacement. If you're unsure about any step or encounter any difficulties, it's recommended to seek assistance from a professional motorcycle technician.