While my clutch is working fine the lever has been loose. I've been taking things apart to lubricate and found a crack in the clutch lever. I see this as failing in the not too distant future. Is there a fix for this or do I need to be looking for a new lever? I do a lot of things but I'm not a welder.

 
 

After a bit of searching I found a new one that seems to be well-reviewed, and ordered it.

www.partsgiant.com/p342318-parts-unlimit...5612#product-reviews

Interesting it has a brass bush in it. Not sure if that is original but then again they did things right early on then start cutting corners due to cost. Someone will know the answer. Great you found a replacement.

I've seen them with bushes and sometimes the bush is threaded and has to be gently tapped to remove it before the lever will come off.

The bushing was originally slightly taller than lever so screw could be tight and lever stayed free. Bushing is so thin it doesn't clamp well in bracket.  (Not sure if it was designed to)

Original bolt was "shouldered" so bushing would rotate on shoulder, not threads.  The "threaded" bushings I've seen have non-shouldered bolts.  I've always thought the "threading" was caused by lack of shoulder on the bolt and crushing the bushing by tightening the bolt. 

Often the shouldered bolts have the bushing slightly stuck to it, again, my theory is bolt was tightened enough to crush the bushing and crimp it to the bolt in the process..  which might have been the way they were designed?

Most replacement levers forego the bushing, which is fine too.  Shouldered bolt is probably best though. 

P.S.  You caught that lever just in time!  Looks like it was ready to break completely at any moment. 

We might be talking at cross purposes here (really, I hear you ask!  ), but the internally threaded bushes (for the non shouldered bolts) weren't threaded all the way up - presumably so, if fitted the correct way round  , the bolt couldn't be over tightened.

 

That's interesting....  if bushing wasn't threaded all the way, how do you get it on the bolt far enough to put the nut on the bolt?

I may have never seen that type.  The ones I've come across seem to have gained "threads" during use. 

Okay, picture wasn't there at first.  I don't recall that type.  Thanks.

They often stay attached to the bolt when said bolt is removed, and therefore give the impression of being a shouldered bolt. However, sometimes they stay in the perch and so have to be knocked out.

Okay, I vaguely remember that style...  not sure I've seen them on an Enduro.  The bracket has a hole large enough for the bushing to fit through or it couldn't come out with the bolt.  Different design than what I think I'm seeing here.