Question about 2005 Honda VFR 800

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Replacing a broken clutch lever on a 2005 VFR Interceptor

Replacing a broken clutch lever.. straight forward bolt on ?? Should I just order one and unbolt the broken one then replace with the new one ? I've worked on MANY "dirt bikes" but haven't worked with a "hydrolic" clutch lever ! Just trying to keep costs down !!

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Thats about it,,,all you need to do if fit the new one but let the clutch adjuster off first so you can fit the cable to the leaver

Posted on Jul 15, 2010

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Your rear wheel is mounted on an offset cam. Part #6http://www.bikebandit.com/houseofmotorcycles/2004-honda-vfr800-interceptor-interceptor-abs/o/m2792#sch303670 Loosen the bolt on the back of the wheel/cam/bearing holder at the back of the swing arm.Part #16 http://www.bikebandit.com/houseofmotorcycles/2004-honda-vfr800-interceptor-interceptor-abs/o/m2792#sch303667 Use tools Part # 15 and 7or 6 (whichever fits the circumference of the cam) together to rotate the bearing cam until the chain has approximately 1 and 1/2 inches of slack from the top to the bottom of its movement in the middle of the chain slack. Then retighten the bolt on the back of the swing arm. Happy Riding

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Info on do it tyour self clutch removal on 2001 mustang 3.8


REMOVAL:
  1. Lift clutch pedal to uppermost position to disengage clutch and brake pedal pivot shaft.
  2. Push clutch and brake pedal pivot shaft forward and unhook clutch release lever cable from clutch and brake pedal pivot shaft and allow it to slowly swing rearward.
  3. Raise and support vehicle.
  4. Remove clutch release lever dust shield.
  5. Disconnect clutch release lever cable from clutch release shaft.
  6. Remove retaining clip, then clutch release lever cable from flywheel housing.
  7. Remove starter motor from flywheel housing, then engine rear plate to front lower flywheel housing bolts.
  8. Remove transmission.
  9. Remove flywheel housing back just far enough to clear clutch pressure plate, then remove housing.
  10. Remove clutch release shaft from flywheel housing by pulling it through window in flywheel housing until retainer spring disengages from pivot.
  11. Remove clutch release hub and bearing from clutch release shaft.
  12. Loosen six clutch pressure plate bolts evenly to release spring tension gradually and avoid distorting clutch pressure plate. If same clutch pressure plate is to be installed, mark plate and flywheel so pressure plate can be installed in its original position.
  13. Remove clutch pressure plate and clutch disc from flywheel.
INSTALLATION:
  1. Position clutch disc and pressure plate assembly on flywheel, noting following:
    1. Three flywheel housing to block dowels on flywheel must be properly aligned with clutch pressure plate.
    2. Bent, damaged or missing flywheel housing to block dowels must be replaced.
    3. tart clutch pressure plate bolts but do not tighten.
    4. Avoid touching clutch disc face, dropping parts or contaminating parts with oil or grease.
    5. Align clutch disc using suitable alignment tool inserted in pilot bearing.
    6. To avoid clutch pressure plate distortion, alternately tighten bolts a few turns at a time, until they are all tight, then tighten to specifications.

  2. Install transmission to flywheel housing.
  3. Install engine rear plate to flywheel front lower housing bolts, then connect clutch release cable to flywheel housing and connect retaining clip.
  4. Connect clutch release lever cable to clutch release shaft, then install clutch release lever dust shield.
  5. Install starter motor.
  6. Lower vehicle, then install clutch release lever cable as follows:
    1. Lift clutch pedal to disengage clutch and brake pedal pivot shaft.
    2. Push clutch and brake pedal pivot shaft forward and hook end of clutch release lever cable over rear of clutch and brake pedal pivot shaft.

  7. Cycle clutch pedal several times to adjust clutch release lever cable

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