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After market levers, fitting advice

voledangler

voledangler

Joined Mar 2011
24 Posts | 0+
Bucks
How do chaps, I just got some lovely new levers for my 2007 rsv, £39 from fleabay and they look and feel like quality despite coming from China. I just need some advice about fitting them. I had a quick go at the front brake and managed to get the original off, however I don't seem to be able to get the pivot/pushrod thing off the old one to use on the new. I have trawled through this forum to no avail, indeed everyone seems to indicate that this is an easy 5 minute job (which I am sure it is) but at the moment I am stuck. Any help would be greatly appreciated..

cheers
Vole
 
Can you stick any photos up? - I did mine a couple of weeks ago with some Chinese ones, and they were a doddle (apart from the original clutch level being a bitch to get off) but I can't picture in my head what you're getting stuck with.
 
It's the little barrel thing with the push rod attached, that goes into the master cylinder. I can't for the life of me work out how to separate it from the lever itself. I will try and get some photos posted up here so everyone can see. I would rather not destroy the originals to get at this part, but if needs be...

Vole
 
mine fell out when i opened the lever as far as it would go ,as i remember it was only just possible but it happened without damage to the originals ...
 
Ok, I'm with you now, I think thats exactly the issue I had on the clutch side. Step by step, I did the following: undo the nut from the bottom of the pivot bolt & remove it. Undo the pivot bolt so that it is free to move, but don't take it out. Push the lever as far forward as it will go, and with a bit of wiggling, the barrel piece should slide out of the top or bottom of the lever. This worked perfectly for me with the brake lever, & took about 3 mins to do. The clutch side was an absolute swine, because the lever wouldn't push forward far enough to 'clear' the barrel. The only way I could get it off, was to take a dremel to it & cut out a small wedge from the top of the lever, to allow enough room for it to push up (I'll post a pic of the hacked lever when I get home, so you can see what I mean). On the plus side, the Chinese shorty replacements are so well engineered that they went straight on in minutes. HTH, shout up if I've made it even more confusing...
 
K20FTY said:
Ok, I'm with you now, I think thats exactly the issue I had on the clutch side. Step by step, I did the following: undo the nut from the bottom of the pivot bolt & remove it. Undo the pivot bolt so that it is free to move, but don't take it out. Push the lever as far forward as it will go, and with a bit of wiggling, the barrel piece should slide out of the top or bottom of the lever. This worked perfectly for me with the brake lever, & took about 3 mins to do. The clutch side was an absolute swine, because the lever wouldn't push forward far enough to 'clear' the barrel. The only way I could get it off, was to take a dremel to it & cut out a small wedge from the top of the lever, to allow enough room for it to push up (I'll post a pic of the hacked lever when I get home, so you can see what I mean). On the plus side, the Chinese shorty replacements are so well engineered that they went straight on in minutes. HTH, shout up if I've made it even more confusing...
Click to expand...


+1 :thumbup:thumbup:thumbup:thumbup:thumbup
 
:biggrinThat sir, sounds like a plan. I shall give it a whirl tonight and report back.

Vole
 
Well that almost worked, I couldn't push the lever back far enough for the pushrod and barrel to come loose. So onto plan B, I removed the lever completely and using a punch (large drill piece) I carefully tapped the pivot bush out of the lever assembly so that it all came apart et voila, access to the pushrod gained. Fitted new lever and it works perfectly. Onto the clutch however and all not so smooth. Same problem with the pushrod/barrel doodad, sorted in the same way, reassembled with new lever however it now appears that the clutch is dragging so that when I kick it into 1st from neutral, bike conks out. More research required I think... On the plus side the new lever are the dogs danglies on looks alone, and I just know when the clutch is sorted my bike will go faster and women wil throw themselves at me etc...


Vole
 
sweet mate .. my clutch totally disengages with the new levers ,it would never do that with originals ? just use the adjuster to sort it pal .....

Photo0761.jpg
 
Last edited:
Shiny bling now fitted correctly, clutch working perfectly. Had to drill out the grub screw on the adjuster, as it seemed to be welded in, but now all is fine. All I have to do now is wait for the skip on my drive to be taken away and I can take my steed back out on the road for a spin. Thanks to all for the advice, wasn't half as traumatic as I imagined..

Cheers
Vole
 
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