clutch lever issue

8 replies to this topic
  • jacque372

Posted 10 July 2009 - 04:34 AM

#1


i fell and bent my clutch lever no dealership in my area has one so i was going to take it off to match one up at a dealership. i can't get the cable end out of the lever i have changed clutch levers a thousand times on my other bikes but this one has me. it has a metal sleeve over the cable end and won't slide out of the lever. do any of you know if the lever of any other bike fits the wr most dealerships have replacement levers for all yamahas but not this one. i would replace the whole clutch assembly but how do get around the clutch switch

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  • YZEtc

Posted 10 July 2009 - 04:56 AM

#2

I'm assuming this is a WR-250R or WR-250X.

First, it sounds to me like your bending of the clutch lever actually closed the cut-out hole where the cable end sits, and this is why you can't easilly get the cable end out.
Once you have a new lever in hand, use a couple of large open-end wrenches to bend the lever back and/or pry open the hole where the cable end sits.

As for getting a new clutch lever, the stock lever is a time-honored part with Yamaha motocross, off-road, and dual-purpose motorcycles.
The part number is 23X-83912-01-00, it was first used on 1983 YZ models, and was used a whole lot on them up until the mid 1990s.
Even then, when they finally changed the part number for the lever, it didn't affect fitment but had to do with a change to the shape of the lever.
It wasn't until the 2000 model YZs and the advent of the adjust-on-the-fly clutch lever/perch where the lever was finally changed to one that was truly different in fitment.

So, to sum it up in your search for a compatable clutch lever, ask for/search for one that fits 1983-1999 YZ-125 or YZ-250 models.
Also, one from any year XT-350 or XT-550 will fit as long as you don't mind black. :)

  • Toddwr250r

Posted 10 July 2009 - 08:54 AM

#3

When i replaced mine it seemed streight forward, when i went to get mine i bought two, every time i buy parts i buy two, broke it once, i'll probably do it again, carry the spares, i seem to go through left side mirror mounts quite quickly

  • jacque372

Posted 10 July 2009 - 03:42 PM

#4

thanks for the help got the new levers bent the old one back up and the cable came right out good call. every dealer i called had no idea about the levers. i have stock piled alot of parts now clutch cables, tubes, levers, shifter, and brake lever. i should be good in a pinch

  • skierd

Posted 10 July 2009 - 06:51 PM

#5

I went with the Zeta folding levers, while easy enough to replace I hope these will make it so I never have to replace them again. My clutch lever was bent 90 degree's forward after my last little fall, haven't had a chance to test the zeta's yet.

New vs. old
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  • Toddwr250r

Posted 10 July 2009 - 08:58 PM

#6

I thought about those, but was put off by the price, how many stock levers do you have to junk out before those zetas become cost effective?

  • jacque372

Posted 11 July 2009 - 03:41 AM

#7

i like the zeta levers i think i might order a set. they cost more but it's better then changing the stock one every time you fall

  • Toddwr250r

Posted 11 July 2009 - 05:00 AM

#8

I found putting the zeta xc hand gaurds on greatly reduced the incidence of bent lever, looks cool with the trick signal lamps in the plastics too

  • skierd

Posted 11 July 2009 - 08:59 AM

#9

Toddwr250r said:

I thought about those, but was put off by the price, how many stock levers do you have to junk out before those zetas become cost effective?

Stock levers are only $7 from various online sources aparently, so 5-7 depending on shipping. How many times do you have to get stuck on a ride with a broken lever (or break one and your spare) before you wish you had the zetas? :p



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