How to Replace a Motorcycle Clutch Lever! From Costs for Bent/Broken Levers to Adjustment Methods: A Comprehensive Guide

Replace a bent or broken clutch lever

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It's an unfortunate fact of life for motorcycle riders that bikes can tip over, whether from an accidental drop or a fall while riding. When a bike falls, the clutch and brake levers are often the first things to bend or break.

Depending on how severely the lever is bent or broken, it can impair your ability to ride.

Improper clutch operation

For manual transmission vehicles, the left lever is the clutch. If the clutch lever is bent or broken, clutch operation may not be possible.

Levers are designed to be operated with minimal force due to the principle of leverage. However, if a lever is bent or broken, you may need to apply excessive force to operate it.

During downshifts, in particular, difficult clutch operation can prevent correct gear selection, potentially leading to a stalled engine at intersections or on low-speed curves.

A broken, pointed tip is dangerous

If a lever breaks, its tip can become sharp like a blade, increasing the risk of injury to the rider.

Although some levers are designed with rounded tips to prevent them from breaking off at the base during a fall, there have been cases where a broken lever pierced a rider, resulting in death. Therefore, a broken lever with a sharp tip is dangerous.

If your lever is broken and has a sharp tip, replace it with a new one as soon as possible, considering both operational safety and overall safety.

How much does it cost to replace a clutch lever?

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If your clutch lever breaks, how much does it cost to have a shop replace it?

We will explain the estimated cost when having major shops like 2-Rinkan or Naps replace it, and the estimated cost if you replace it yourself.

Average cost when having a professional replace it

As a reference for having a shop replace your clutch lever, we will introduce the costs for requesting a clutch lever replacement at 2-Rinkan and Naps, respectively.

The time required for replacement is typically same-day if the shop has the clutch lever in stock. If not, it will take approximately 2-5 days (or about 1-10 days if there's a long holiday like Golden Week).

Cost for replacement at 2-Rinkan

The labor charge for a clutch lever replacement at 2-Rinkan is 1,980 yen (including tax). If you bring your own lever, the replacement charge is 3,960 yen (including tax).

The replacement takes approximately 15 minutes. If fairing removal and reattachment are necessary, additional fees will apply.

Reference: https://2rinkan.jp/pit/kouchin/brake_handle/

Cost for replacement at Naps

At Naps, the labor cost for replacing a clutch lever, when no fairing removal or attachment is involved, starts from 1,100 yen (including tax, lever cost separate).

The work time is approximately 15 minutes if no fairing removal is required. The replacement cost and work time may vary slightly depending on the motorcycle model.

Reference: https://www.naps-jp.com/shops/pit/handle/

Replacing it yourself

If you replace the clutch lever yourself, the only cost required is that of a new clutch lever, and no labor charges are needed, making it cheaper.

If you have the tools and are confident in your ability to replace it, and you want to save as much money as possible, it's a good idea to try replacing it yourself.

For those considering replacing it themselves, the next section explains how to replace a clutch lever, so please refer to that as well.

How to Replace a Clutch Lever Yourself

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We will explain how to replace a clutch lever yourself.

There are mainly two types of clutches: cable-actuated levers and hydraulic levers, and the replacement procedure differs for each. However, hydraulic levers are easier to replace than cable-actuated ones.

First, we will explain the replacement procedure for a cable-actuated clutch lever step by step.

Cable-actuated clutch lever

A cable-actuated clutch lever is a type where a cable for clutch operation extends from the lever, a common method for smaller displacement bikes and older models.

The general replacement method for a cable-actuated lever follows these steps:

1. Remove the lock nut
2. Loosen the cable slack adjuster
3. Remove the cable from the lever
4. Attach the cable to the new lever
5. Install the lever and check its operation

In addition to genuine parts, there are various types of clutch levers available, so it's a good idea to choose one based on your preference or practical considerations (such as those designed to bend in case of a fall).

Step 1: Remove the lock nut

First, loosen the lock nut located on the back of the bolt that secures the clutch lever.

The clutch lever is secured by a single bolt, which is then held in place by a lock nut to prevent it from loosening. Therefore, you need to remove the lock nut before removing the securing bolt.

When loosening the lock nut and securing bolt, be careful not to strip the head, as this could make it impossible to remove. Proceed cautiously.

Step 2: Loosen the cable slack adjuster

Loosen the slack adjuster located near the base of the clutch lever.

The adjuster consists of a large ring and a smaller ring attached to it, with the larger ring serving as a locknut.

Both the base of the clutch lever and the large and small rings have cutouts for the cable to pass through. When loosening, align these cutouts to allow the cable to be removed.

On older bikes, the rings may be rusted and stuck. In such cases, spray rust remover and let it sit for about 5 minutes to make them easier to remove.

Step 3: Remove the cable from the lever

Once the slack adjuster is loosened, remove the clutch lever so that the cable can be detached from the cutout position.

After the lever is removed, detach the cable. The cable is simply seated in a hole, so it can be easily pulled out by paying attention to its orientation.

Once the cable and lever are separated, check the cable for damage, rust, or fraying. If fraying is found, replace the cable with a new one to prevent problems such as breakage.

Step 4: Attach the cable to the new lever

Once the cable is removed from the clutch lever, replace it with a new lever and reassemble by reversing the removal steps.

First, assemble the cable onto the lever. It's recommended to apply a thin layer of grease (such as multi-purpose grease) to the movable parts before assembly, as this will allow for smoother clutch operation.

Step 5: Install the lever and check its operation

After the lever is installed, check if the clutch operates correctly and if the clutch slack is optimal.

Too much clutch slack can lead to improper clutch disengagement. Adjust the adjuster that was loosened during lever removal to achieve optimal disengagement.

Hydraulic clutch lever

A hydraulic clutch lever operates the clutch using hydraulic pressure and is found on high-spec motorcycles such as supersports, sport naked bikes, and large models.

Unlike cable-actuated systems, there is no clutch cable, so the lever can be easily removed by simply unscrewing the bolt that secures it. After lubricating the movable parts, simply attach the new lever once the old one is removed.

Once the lever replacement is complete, test its operation on a road with light traffic to ensure it functions correctly.

How to Adjust a Clutch Lever

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Adjusting the clutch lever slack is easy, and proper adjustment can improve operability and allow you to set the clutch engagement point to your preference.

Also, while slack adjustment is generally only possible with cable-actuated systems, you can adjust the lever position on hydraulic systems by replacing it with a lever that has an adjustment dial.

Adjusting clutch slack

There are two ways to adjust clutch slack: main adjustment and fine adjustment. First, perform fine adjustment, and if the slack still cannot be adjusted sufficiently, then proceed with main adjustment.

[Fine Adjustment] How to adjust clutch slack

Peel back the rubber cover (dust prevention cover) at the base of the clutch and adjust the adjuster inside to change the amount of play.

The large ring next to the adjuster is the lock nut, and loosening it allows for adjuster adjustment.

[Main Adjustment] How to adjust clutch slack

For main adjustment, there is an adjustable point on the engine side of the clutch. By turning two nuts, you can also adjust the clutch slack.

Follow the clutch cable to locate the part secured by nuts near the engine. Adjusting these nuts will change the amount of slack. If the slack cannot be fully adjusted with the fine adjustment, then adjust it from the main side.

Adjusting the clutch lever height

To adjust the height of the clutch lever, simply loosen the bolt that secures it to the handlebar.

The clutch lever holder is secured to the handlebar with a bolt. Loosen the securing bolt (you don't need to completely remove it) and rotate the entire lever holder to find your preferred position.

For positioning, sit on the bike as if you're riding and make fine adjustments. Once the position is set, tighten the bolt to secure it.

The brake lever can be adjusted in the same way. However, check the lever's position before starting the work so you can return it to its factory setting.

FAQ about clutch lever replacement

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This section compiles "frequently asked questions" and "answers" regarding clutch lever replacement.

Please refer to it if you are considering replacing a broken clutch lever, or if you simply ride a motorcycle.

My clutch lever feels heavy. Should I replace it?

If your clutch lever feels heavy, lubricating the movable parts may improve the situation, so it's recommended to try that first.

If the heaviness doesn't improve after lubrication, consider replacing the clutch lever.

If the clutch lever is too far, should I replace it or adjust it?

If the clutch lever feels too far, first try adjusting the clutch slack using the adjuster at the base of the lever.

In addition to the adjuster at the base of the lever, you can also adjust the clutch cable slack on the engine side. If it's still too far even after adjusting both, it's recommended to consider replacing it.

The rubber cover for my clutch lever is gone...

If the rubber cover for your clutch lever is missing, order a replacement as soon as possible and put a new cover on.

The rubber cover protects the movable parts near the clutch lever and cable connection point. Without the cover, dust and debris can easily enter the movable parts, and the clutch cable's smooth operation will worsen.

Dust tends to adhere to the movable parts due to the grease and other lubricants, which can easily lead to problems. Therefore, get a new cover as soon as possible and restore it to its original condition.

Is it okay if the clutch lever is broken?

If your clutch lever is broken, you should replace it with a new one as soon as possible.

The tip of the lever is rounded, which reduces the risk of injury in the event of a fall.

Especially if the lever is broken and its tip is sharp, it can be dangerous and cause injury even from a simple fall. So, consider replacing it promptly.

My clutch lever broke on the road... What's the emergency fix?

If your clutch lever breaks while you're out and you don't have a spare, you can make a temporary fix by securing a metal object (such as a small spanner, 10-12mm) to the lever with strong vinyl tape.

If you don't have vinyl tape or a suitable metal object, and if it's safe to ride, proceed cautiously. Otherwise, consider using roadside assistance services like JAF.

Summary

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We've explained how to replace a motorcycle clutch lever if it breaks due to a fall or tip-over.

We've also covered the estimated cost of having a shop replace it, how to replace it yourself, and how to adjust the slack, so please refer to this information.

If you frequently break levers from falls, it's a good idea to keep a spare lever as a stock item. Also, having on-board tools and vinyl tape means you can perform an emergency repair if a lever breaks while you're out, so it's wise to be prepared.