Heavy clutch on Norge

[DoubleGuzzi]

At a loss now what to do as that clutch lever pin does not want to come out.

I feel your pain.
Are you doing this with the assembly fitted on the 'bars? Reckon you've gotta remove the assembly now, if not already. Leave inverted, with Plusgas on the threaded portion for a day, or two. Try to squirt a little between lever and perch too, for good measure.  Reassemble on the 'bars (for more purchase, or a large vice may suffice), then try to loosen again. The Plusgas tends to be really effective and worth persevering with -  I think that I'll try XCP One, when the Plusgas runs out.

Say goodbye to the pin...
For drilling out, I'd go from the underside (threaded side), then a reverse drill will not be required. Drill at least as deep as where the thread goes through the perch. Gradually increase drill size until just below the diameter of the thread - it's gotta be looser at that stage! Worst case scenario is the perch thread will be knackered but that's not a major issue, given the use of the nylon locking nut. The clutch lever may 'rattle' a bit from being too loose, though could be shimmed.

Just trying to help and others may have better plans.
 


P.S. If it's any consolation, I currently have a similar issue on the Breva, with the pivot pin at the opposite end of the cable! It's seized on the clutch arm and pivoting on the casing instead. I'm trying to keep my cool/patience 

[Huzo]

Really the problem should be easy to dial into.
If you are not sure where the binding is coming from, just undo the banjo at the clutch m/c, thus removing any possible causes further down the line and isolating the lever mechanism.
That’ll tell you…

[DoubleGuzzi]

.. just undo the banjo at the clutch m/c ..

After draining the brake clutch fluid! 

[Further thought]
Could it be that some eejit has put a liberal dose of thread lock there? Guys here will know the best stuff to dissolve it; acetone, brake cleaner, etc.

[Oca Grassa]

I'd not do any of that with the clutch master cylinder on the bike. Remove it and put it in a bench vise. You likely have some corrosion build up along with some surface wear on the screw/pin.

 I've removed them before both on my Norge and a couple of my Ducatis where the pin is no longer round but oval and worn in the middle, sometimes with a sharp "step" in the metal. Had to soak the thing in PB Blaster for a while before the threads broke loose. Even then it was a PITA unthreading those few tiny threads at the bottom of the pin.

 MG Cycle and OPP both sell replacement pins for about $8 US. The clutch master may need a rebuild at this point as well so getting a seal kit might be a good move. Just in case you have to add a bunch of heat to get the pin out.

[DoubleGuzzi]

I'd not do any of that ... etc. etc.

Wot eye sed.