Both my clutch and brake levers have some up and down play, causing them to vibrate when accelerating. I have remove the retaining pin and bolt, making it obvious that the bolt is about 1/16" too long. They are factory, and can be pushed up and down when installed tight (as tight as they can be). I can grab either lever and shake them up and down. Does anyone have any suggestions to resolve this? Thanks in advance.

 

How far do they move? I have some movement on mine but not excessive. If you remove the pin, there should be a plastic sleeve where the pin goes through, maybe it is worn out or missing?

 

They move up and down about a 1/16 of an inch, but its enough to really make some serious noise. My pipes are not very loud, and this metal on metal vibration sound actually stands out from the expected sounds. Its quite irritating.

 

I checked the inserts, and they are not worn. Good idea though. The movement is actually up and down, leading me to believe that there should be a rubber spacer between the inner portion of the lever housing (top and bottom) and the lever itself. But, this might obstruct rotation. The rod that holds the lever in place with the spacer ring, simply seems too long.

 

There should be a thin anti-rattle clip that the pin passes through and snugs up the slack...maybe

 

Yes, there is a pin, but it fits into a notch that is actually causing it to lock in place with slack.

 

What year bike are we talking?

 

Its a 2003 - 1200 Custom. I just spent some more time trying to dampen sounds, and have actually found that the lever is only a part of the issue. The mirror is vibrating the most, with some metal on metal sounds down the front forks. It might be one off balance, causing it to transfer. I am playing with the mirror, now, but I think it might be loose internally. Thoughts. Its not free moving, to the head of the mirror seems to be intact.

 

I would invest in some high quality ear plugs and leave those leevers alone.