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Thread: Replacing the clutch lever - how do I get this part off!

  1. #1
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    Replacing the clutch lever - how do I get this part off!

    Ok,

    So apparently Aprilia and I have a very different idea of what constitutes a clutch "lever", and I now know why some people are not fans of this whole hydrolic clutch thing. So I've removed the (remnants of the) broken clutch lever:



    The only problem is that it came with the... I dunno. Hydrolic actuator? I tried looking at the fiche on AF1's site and apparently Aprilia considers this huge mechanism to be the "clutch lever" that include the actual lever and several additional parts. But that's beside the point. Right now all I need to do is get this part out so that I can get the new lever on. It's got what appears to be a flat head screw:



    I can get it to turn maybe a half-turn in either direction, but that's not doing me much good. How do I get this off of the broken lever and onto the new one?

  2. #2
    apriliaforum expert kzmille's Avatar
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    There is a small set screw in the end of the barrel that locks the rod. Remove with a small hex key. Use heat as thread locking compound was used on installation. make sure there is adequate free-play between the rod and MC piston while assembling.

  3. #3
    apriliaforum expert Nooj's Avatar
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    Can confirm that, there's a tiny grub screw to undo that holds the plunger in place.

  4. #4
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    I was afraid you'd say that. I saw it last night and in my hex set I have one that just a touch too small, and one that's a touch too big. I'll see if anyone in IT has one that'll fit.

  5. #5
    apriliaforum Junkie anthonyk's Avatar
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    If not, I've got one in the garage. Let me know. It's a 1.5mm.

    Anthony
    '01 Falco

  6. #6
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    Ok, really Aprilia? You couldn't have just kept it to whole numbers? What's a guy got to do?!? I used to think I had more tools than I needed at one time.

    <sigh>

    Someone remind me what the benefits of a hydrolic clutch are again?

  7. #7
    apriliaforum expert D-Rider's Avatar
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    Quote Originally Posted by budoist View Post
    I was afraid you'd say that. I saw it last night and in my hex set I have one that just a touch too small, and one that's a touch too big. I'll see if anyone in IT has one that'll fit.
    Yeah - I attacked mine with an allen key, didn't want to move and I succeeded in destroying the allen socket .... rendering it unadjustable ....

    Fortunately I've now got hold of another one to put on there and I can keep my unadjustable one as an emergency spare.

    Just take care with it - certainly heed the advice to use some heat.

  8. #8
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    So hold under a hair dryer for say... 30 seconds to a minute, then attempt to remove?

  9. #9
    apriliaforum expert kzmille's Avatar
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    A heat gun would be better but if that's all you have it won't hurt.

  10. #10
    apriliaforum expert SoulDaddy's Avatar
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    I heated mine up by holding a soldering gun on it for about 30 seconds.


    At least with a hydraulic clutch you get a little warning that it needs your attention as opposed to a cable snapping on you when you least expect it. That's all I could think of.
    "If you make a habit out of slathering yourself in bacon grease and streaking through the tiger habitat at the zoo, is it really a surprise when you end up as a tiger turd?"
    -JodyH


    Max reflects.
    Get your mind right.

  11. #11
    apriliaforum expert Firebolter's Avatar
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    Quote Originally Posted by budoist View Post
    Ok, really Aprilia? You couldn't have just kept it to whole numbers? What's a guy got to do?!? I used to think I had more tools than I needed at one time.

    <sigh>

    Someone remind me what the benefits of a hydrolic clutch are again?
    Always a constant feel and no cable to stretch and break. Never needd adjustment. I love them. Even my KTM dirtbikes have them........And it is Mr. Brembo or Magura (can't remember which) that made them with the 1.5mm allen key, not Mr. Aprilia!
    2014 BMW F800GSA
    06 Husky SM610 Hooligan Jr.
    07 KTM 525 EXC
    13 Husaberg TE 300
    11 Beta 300 Race Rep 2T Trials
    75 Suzuki RL250--OldSchool Trials & 1971 BSA 250 Trials

    Now there are 2 "Cylinders" on my ride, parallel BABY!!

  12. #12
    apriliaforum expert Nooj's Avatar
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    1.5mm? Sounds reasonable. Don't forget that Europe went metric in the last century

  13. #13
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    FB, ok then. Mr Bloody freaking Brembo. I dunno about never needing adjusting. Have to bleed the system and monitor the fluid levels. Dunno how much more/less intensive that is compared to clutch cable maintenance.

    Am I hijacking my own thread? Maybe, but it's midnight. What else am i supposed to do. I've watched all the porn on the Internet already.

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