Clutch and brake issues after new levers ?

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Joined
Aug 13, 2009
Messages
736
Location
Didcot UK
ARRGGHHHHHHHH. and GRRRRRRRRRR.

The new levers feel lovely.... really impressed. Took the bike into the office today..

Got about 5 miles and going down the lanes I thought the bike had died as I had no power at all.... ???? Pulled over and the brakes were locked solid. I then noticed that the toolkit is woefully short on the right things to take the levers apart... so a little 5 min wait for the brakes to cool down and decided to head back home to drop the bike off and get the car.
Then on the way back I noticed that the clutch was starting to slip as I nursed the bike home without touching the front brake LOL. Anything over 4000rpm and it was slipping.

Aprilia 2002 RSVR/Tuono Brake & clutch Levers | eBay

That's the listing I bought them from... As far as I can gather they should be the same from 2002-2010 ?

THere's VERY little you can do wrong when installing, as long as the push-pin is inserted correctly, you're good to go... So I can only assume they're slightly incompatible and dragging both slightly ?

Hmmmmm

Will take apart tonight and hope I can find the standard levers.
 
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I recall someone else fitting pattern levers and having similar problems.The problem was not the push pins,..it was the levers.They were slightly the wrong shape and had to be filed down to fit correctly.
 
I wasn't sure from the description if these ones are pattern or standard. Looking at them, they could easily be either.
 
I've sort of negated the brake aspect and bought a new master cylinder kit LOL But i'll still take things apart later this evening and analyse.

New Frando 19mm Radial brake master cylinder ZX10R CBR1000RR GSXR R1 RC8 FZ1 | eBay

$_57.JPG
 
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So I stripped it all down, the clutch I was able to re-adjust using the pin to be correct due to the pin having a threaded end, meaning I can screw it in further. The brake lever pin however is simply an 'insert to the shoulder' it has a little shoulder on it, so that's how far in it goes, no discussion no debate. So the solution was to fit the shorty back on there. Both are now working and operating perfectly :)

Although they are mismatched LOL.

Good news is, I can live with the clutch being long and the brake being short, I don't mind a shorty brake lever, but the clutch was irritating me lots.

So I've also cancelled the purchase for the now unnecessary new brake system as it's fixing a problem that no longer exists.

If I desire over winter I could trim the lever or the push-pin slightly which would resolve the brake lever and mean I could run long on both.... but we'll see, maybe.
 

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