Floppy Lever Fix

[montmil]

Have you got floppy Magura clutch and/or front brakes levers? Tired of seeing them bouncing up n' down as you cruise the back roads? Tightening the nut on the pivot pin won't fix it.

BMW Part # 32.72.1232662 is a $3.86 part. Kinda pricey for a nylon bushing, but the fix is so nice.

Check the egg-shaped nylon bushing I just now pushed out of the clutch lever. Use a larger socket below the lever as a support. A smaller diameter socket will drive the old bushing out with a couple gentle taps from a small mallet. Install is the same process.

Now here's where the trick comes in... After pressing in the new nylon bushing, it will be an overly tight fit to the lever's pivot pin and will not allow smooth lever action. The new nylon bush must be reamed to fit so as not to bind on the pivot pin.

My pivot pin measured 0.312 inches in diameter using my vernier caliper. I located an Irwin-branded 5/16" / 0.3125 brad point drill bit. Brad bits have sharp spurs that cut clean, accurate holes. Used by hand to ream the nylon busing to a correct size, the bit produced twin nylon ribbons sharp as needed. Suggest not attempting to use a conventional drill bit for this job as it will probably hog in and ruin the bushing. If you have a 5/16-inch straight reamer, you're golden.

[Bob_Roller]

Never noticed there are bushings in the bolt holes before .

[montmil]

Never noticed there are bushings in the bolt holes before .

Neither did I until this topic popped up on the Airheads Digest.

[marcmax]

I found out about that particular bushing when I was taking  my levers off to refurbish the perches. It must have been training for the Olympic team because it sprouted legs, took off and was never seen again. I found a suitable substitute in the local hardware store bin. Correct OD put too long and wrong ID, both easily fixed. And I think it was under a dollar. It definitely makes a difference.

[AlfromNH]

Yep, just replaced mine on the clutch side. It was a tight press into the lever, and once in place the bore was too tight. I opened it up with the correct size drill, 5/16 IIRC

[Luca]

I too did this recently when doing a little rehab work on a R60/6.  Those loose bushings will also take away some of the lever's useful travel range.  BMW put the wave washer between the lever and perch to keep the levers from flopping up and down as well.

Didn't know about the brad point edges, Monte.  That's nice to know.  I have a couple sitting in my Ryobi bit set (I prefer to think of it as premature scrap metal) and I just thought they were made to keep the bit from walking.

The bushing and washer are one of those nice design features.  $4.00 US in expendable parts keeps the much more expensive lever from wearing out.

[georgesgiralt]

Hi Lads,
Could you, please, post a picture of "brad point edges" drill bits ?
As a French living in France, I can't identify this nice bit of gear I would love to have ;-)
Thanks in advance !

[AlfromNH]

I guess I wrote my post without having read Monte's all the way thru... I'll blame it on my wife talking to me at the same time

Georges, there's a pic of different drill bits in this thread:

http://www.seymourduncan.com/forum/showthread.php?259224-Mounting-ring-(vintage-non-standard-size)-Hole-Melt-or-Drill

[montmil]

Note the sharp "spurs" that start cutting the o.d. at the same time as the pointy brad.

I do quite a bit of custom cabinet and furniture design and construction. These bits are my usual "go to" when I need a clean bore. They are similar to my Forstner bits, but less expensive.

[georgesgiralt]

Thanks ! I'm less dumb than yesterday  

[montmil]

...  BMW put the wave washer between the lever and perch to keep the levers from flopping up and down as well.

The wavy washer goes on the outside of the lever perch and under the pivot pin's nut. Any washer found within the perch's slot for the lever was likely a PO's attempt to cure the wobbles. BMW parts fiche confirms.

And since I was just on Bob's BMW site, I also noticed that the list of choices under the "Shop" tab no longer includes the word, Fiche. Now says Factory Parts Diagram. Is this another little chip in the dumbing down of America?

[Barry]

BMW put the wave washer between the lever and perch to keep the levers from flopping up and down as well.

I always thought the same. There is even a shallow recess in the top of the lever for the washer to sit in. Why would they do that if no washer was intended.

[Bob_Roller]

That's where I've been placing the wave washer, seemed like it was meant to go there .

[montmil]

Would the fiche -Oh! Excuse me... would the Factory Parts Diagram lead us astray?

[Barry]

Never noticed there are bushings in the bolt holes before .  

You may be remembering correctly Bob at least in part. On mine there is a bush in the clutch lever but not in the brake lever. The pivot pin bears direct on the lever metal. Can't say there was much wear though.  The pin is the same diameter in both cases and both have the recess in the lever for the wavy washer.   I cleaned and greased both levers at the last annual service and noticed the difference.