lengthened clutch release lever: details
Posted: Tue Sep 06, 2011 7:14 pm
John, good point about the extra stress the longer stem will put on the bearing and seal. And now I've damaged the bearing seal by snagging it with the notch of the stem while pulling out the stem. Bought a new seal, can't get the old one out. The Kawa manuals show the seal in a blowup, but say nothing about how to get it out. The Clymer shows a flatblade screwdriver prying out the seal, but I can't get any tool between the bottom of the seal and the top of the bearing, and the upper rim of the seal just bends and gives way when I pry there.
Cyclepedia shows a seal pick prying out the seal. I have one of those but I can't get a purchase with it either. I'm just tearing up the seal, but it hasn't budged. Any idea how to loosen up that seal so I can get it out?
Btw, how far did Mike extend your lever? - James
On Sep 6, 2011, at 4:22 PM, Cox, John wrote: > That all makes sense though I don t know why the stem is longer. Even if there is no form/fit issue inside the case the longer stem will exert a higher radial load on the bearing and seal. > > I have a lengthened actuator that Eagle Mike Cowlishaw modified. I think he did a small batch. > > > Very Respectfully, > > John Cox > > From: DSN_KLR650@yahoogroups.com [mailto:DSN_KLR650@yahoogroups.com] On Behalf Of JWF > Sent: Tuesday, September 06, 2011 2:59 AM > To: DSN_KLR650@yahoogroups.com > Subject: [DSN_KLR650] Lengthened Clutch Release Lever: Details > > > Question about the clutch release lever: What part inside the case does it rest on when installed properly? I can see what might be a shelf inside the case, on the inboard side. I felt it with the end of a cable tie, at about the height where that shoulder on the lever's stem would ride when fully seated. The shoulder on my stem isn't noticeable worn, but then it's bathed in oil. > Is this right? I've never seen inside the clutch cover, would rather not remove it to answer this question. > The reason I ask: I bought an aftermarket modified clutch release lever. It's the stock lever assembly with the lever lengthened, like in KLRCary's article (though he lengthened his by 0.300" and this one is lengthened 0.600"): > http://klrworld.com/forums/index.php/topic.51.0.html> > The stem on the new part is longer (taller) than my stem. It works the clutch but sticks up about 1/8" above the top of the case. Because it didn't fit the same as my old one, I only worked the clutch with it twice before removing and inspecting it. There was a horizontal score mark on it, about at the level of the needle bearing. (There's no such mark on my old stem.) The bearing looks good after 10,500 miles, and it's only replaceable by removing the clutch cover. The seal on top of the bearing looks ragged, and I can replace it from above. It has a steel spring inside it, so of course I'm hoping that's what scored the paint on the new part, and I'm replacing it this week. > Does any of this make sense? The part is from Ernie Bell, Dakota Motorsports: > . Thanks- JWF > > [Non-text portions of this message have been removed]