Can someone please advise how I remove the 'cylinder' out of the clutch lever on my Panigale please. Clearly it will slide out once the hinge part clears the lever, but that's my issue, it won't hinge any further out than what is shown in the picture below. I'm missing something obvious I'm sure, but before I bugger up my lever completely I thought I'd ask for some help. Thanks in advance...
Ok, I've worked out that the bush holding the hinge to the lever needs to be pressed out. Just need to find a way of pressing them out now! Edit - One very basic homemade press later and everything is taken apart and new levers on no trouble!
spent ages working out how to get this off and fit my new Evotech stubbies yesterday any tips please?
I'll take a picture of the homemade press I used a little later if that's of any use? Basically you just need to push out the main pivot bush. I used my 'press' - which is a narrow steel rod with some plates, then a small socket that fits over the bush and a nut over the top of it all to be able to tighten and therefore press out the bush. A picture is worth a thousand words and all that, I'll get you a pic...
Ok...this might not be a huge help because it was all in bits in the tool box, but essentially this is what I put together - just perhaps not in this order! I think I used the U shaped brackets underneath to give the bush some room to actually come out and the tightened the nut to over the top of the other U brackets which then pushed that bush with the flange down and pushed the bush out of the lever. Sorry if this doesn't help!
cheers matt, just to be clear the "bush" that you refer to is the inner ring pictured above where you've circled on the first picture in this thread?
I'd like to think I tried that, but I can overthink these things sometimes! I'm pretty sure/hoping it won't!
if thats that little screw behind then i tried that and it didnt release the cylinder far enough to pull it out
If you lube the bush with a little oil first you can usually hold the lever in your hand with an appropriate sized socket over the bush and tap it out with a small hammer. The bushes are an interference fit but not normally very tight:
I struggled and struggled with this as well and nearly gave up. Then I discovered the solution quite accidentally. The problem is that you are thinking as I did that the plunger assembly is supposed to slide up or down out of the cylindrical housing built into the lever. But actually the whole cylindrical plunger part simply pops out through the open part of the half-cylindral housing that it sits in. It slips out of the open part of the "C". See photo attached in the following post. The cylindrical part of the plunger assembly is actually polyurethane. It is hard but it just soft and compressible enough to allow it to squeeze through the open part of the aluminum cylindrical housing of the lever handle. Try this: Put the lever back on the bike, replacing the bolt and nut--only, this time, don't insert the plunger into the rubber diaphragm and hole of the piston (I'm not sure if that what it's called). Leave it out so it can swivel back and forth freely toward the handlebar end. Now gently press on the handle (just as you would to activate the brake or clutch). Because you've left the plunger outside of its hole, it will swivel back toward the handlebar end, and the whole clutch/brake control assembly and housing will act as a vice to squeeze the plunger assembly out of the lever! It literally pops right out, so make you don't lose it. You will say, "duhhh!" after you try this.
