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Save those expensive clutch and ignition cases
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TOPIC: Save those expensive clutch and ignition cases

Save those expensive clutch and ignition cases 8 years, 5 months ago #4938

After taking Hornets sound advise and purchasing a couple of clutch and ignition case savers for the DRZ, I came across this handy tip.
I doubt if case savers are manufactured for every single machine out there so this might be useful to some or all of you.
Below is a brief summery of how to.

Bike pictured KTM,
Aim To make a case saver that stops the clutch case getting holed by the brake pedal in a spill (An ocurrance which happens more often than you think by all accounts).
MaterialsAn old hand guard or something of similar material eg mudguard etc, zip tye's, bailing wire, lock wire.
Tools Hack saw, drill, pliers.
Time Approx 15 mins.
Method #1 Take the afore said base material and cut it to the rough shape of a hand guard / leg of mutton (only smaller) to fit behind the brake pedal as per pix.
One thing to remember at this stage is to make sure that the raised portion (front upper) which sits behind the actual foot area is tall enough to be guided by the case in it's fully depressed mode; this is to prevent something that is shorter inadvertently getting stuck under the case and staying down if for example the guard was to be moved in a drop or fall, worst way it could leave the brake fully locked on and we don't want that now do we?
#2 When satisfied that you've positioned it correctly, mark out dot's - hole guides either side of the pedal (if you want to secure by having the outline slighty larger) or alternativley cut a couple of notches to aid the zip tyes or wire from slipping as per the pix.
#3 Zip tye or lock on using the wire.
#4 Stand back and pat yourself on the back for a job well done.
The original author swears that this has saved his cases on numerous occasions, and given the material and shape I can see that it would dissipate the load quite nicely.
In any event it's virtually free if you happen to have the base materials hanging around waiting to be binned, or a few could club together and buy a base part for cutting up?
I intend to see if it fits the DRZ with the new guards in place, and will definitely fit one to the XR.
Any way enough from me let the pictures do the talking.





THE END OF THE ROAD IS THE START OF THE FUN
Last Edit: 8 years, 5 months ago by Trevor Pastrami.
The following user(s) said Thank You: Twintec, Howlingmoon, Norm De Plume

Re: Save those expensive clutch and ignition cases 8 years, 5 months ago #4939

  • hornet
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  • Greenlane Bimbler
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I should have mentioned that ive also taken the levers off and rounded off any sharpe edges

Good post mate
Id rather be cleaning my very muddy bike than driving a car

Get riding or get dying
The following user(s) said Thank You: Trevor Pastrami

Re: Save those expensive clutch and ignition cases 8 years, 5 months ago #4940

hornet wrote:
I should have mentioned that ive also taken the levers off and rounded off any sharpe edges

Good post mate

Thank you.
Another useful tip there mate, I shall also round mine off before use.
THE END OF THE ROAD IS THE START OF THE FUN
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