Honda XL/XR Clutch/Brake Lever

by willmacneill, published

Honda XL/XR Clutch/Brake Lever by willmacneill Dec 12, 2012


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A clutch lever I designed to replace a broken part on my 1983 Honda XL200. I believe it will fit many other models of Honda dirtbikes.


Clutch.stl is the full mockup.
Clutchprint2.stl is the shortened version for printing on the MakerBot Thing-O-Matic, with built in support material.
I have included the inventor drawings in case anyone wants to tweak them.

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I'm going to try making it out of Taulman Bridge soon. That may be the perfect material.

i have been running these on my xr650r. i am currently using one printed with taulman 645 nylon. it flexes alot and doesnt give very good clutch feel but can take alot of hits. i believe it will make a good emergency spare because it will always flex on the hits and not break. my first one was out of abs but was a very bad early print. it worked well but needed alot of extra shaping with a knife and broke when i took it off to try the nylon. i am going to try the taulman tglase pett next and maybe polycarbonate later.

How long did it last?