To Jimmy-Rig or Replace, That is the Question

Taking an XJ650J on a 7,000-9,000 mile trip starting the end of May. In the process of completely going through the bike and have run into a little issue with my clutch lever perch (not sure if this is the exact technical name, basically the clutch handlebar assembly that the clutch lever and left mirror are all a part of).

Basically over the last few decades the clutch lever being pulled has eroded away the metal within the perch. This causes there to be a lot of up and down play in the clutch lever (thing basically flaps in the wind). To point out the obvious, this is pulling on the clutch cable at an improper angle and.....much to everyone's surprise, an 8-month old cable snapped on me in the garage this morning.

Now to the question. I have had a few people (mechanic and a welder) tell me we may be able to put some kind of shim in there to stop the abnormal free play and basically replace the eroded metal. Option #2 is I found a shop that will send me a brand new original in the plastic for $90 bucks shipping included. What would the XJ community out there do, try out the shim and if it doesn't work replace her or go straight for the full replacement before a big trip.

Any input is much appreciated, happy Sunday.

 

Pictures would make it easier to answer.
Shiming the handle to take out the slop sounds viable, but if the condition is such that the shim doesn't prevent continued wear. Well . . . Replace it.

If the shim thing works consider running a second clutch cable next to the existing one and zip tie it in place. That way you would be set for a quick and easy roadside repair.

<edit> I just re-read your post - 7-9k Miles is a long go, perhaps replacing would be one less thing to worry about.

 

@Stumplifter Attached a photo here, best shot I could get using a headlamp while holding the clutch handle up with my hand to show the pretty obvious wear & tear.

Like the idea of the back-up clutch cable system...but exactly, if I repaired/replaced everything on an older bike before this big trip I could possibly have new bike (hah), but peace of mind that my clutch cable won't snap in Death Valley is nice.

 

That's not wear. Someone cut the perch so they could use a non OEM lever.

 

Was hoping someone would point out the obvious that I was overlooking, thank you @k-moe.

It looked like there was way too much room for erosion to be the cause, looks like replacing may be the best bet. Any input out there on if $90 sounds about right for this part?

 

For a NOS part, $90 sounds right. I would not pay that though. A used example will cost far less. Remember that you will need the correct lever as well.

 

+1

 

Send me a private conversation.... I may have extra around.

Dave fox ( in NY...around here, " North Country" is only abou 1/2hr away--- where are you located?)

 

Wanted to pose another question to the masses. Attached a photo here.

Have had a small oil leak coming from the valve cover gasket for a bit, but in the past a replacement of the cover and gasket has fixed that up. Not sure how big/small of a problem the leak in this photo is. Pic was taken from the front, little rubber foot mount on the bottom left is the foot rest on the aftermarket engine guard.

Any suggestions are much appreciated.

 

When you replace the valve cover gasket, you need to also replace the donuts.......