Replacing clutch & brake levers - Revision history

Bokonon: /* Clutch lever */

2011-02-12T10:57:19Z

Clutch lever

← Older revision		Revision as of 06:57, 12 February 2011
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	[[Image:13adjuster2.jpg\|170px]]		[[Image:13adjuster2.jpg\|170px]]

	Now you can remove the ~~old~~ cable ~~from the handle bar end~~. Pull the cable out of the adjuster screw, pulling away from the handle. Align the cable end with the slot and pull the cable end down, out of the handle as shown.		Now you can remove the cable. Pull the cable out of the adjuster screw, pulling away from the handle. Align the cable end with the slot and pull the cable end down, out of the handle as shown.

	[[Image:18cableout.jpg\|170px]]		[[Image:18cableout.jpg\|170px]]

Bokonon at 23:25, 30 October 2009

2009-10-30T23:25:15Z

← Older revision		Revision as of 19:25, 30 October 2009
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	====Clutch lever====		====Clutch lever====

	Before you start, make sure to take careful notice of how the [[~~Cleaning and servicing~~ the clutch switch\|clutch safety switch]] is installed. If you mess it up on the reinstall, it may be a while before you ride again. You have to make sure to not break off the plunger, which turns the switch on and off.		Before you start, make sure to take careful notice of how the [[Checking the clutch safety switch\|clutch safety switch]] is installed. If you mess it up on the reinstall, it may be a while before you ride again. You have to make sure to not break off the plunger, which turns the switch on and off.

	[[Image:levers15aaa-3.JPG\|150px]]		[[Image:levers15aaa-3.JPG\|150px]]

Bokonon: /* Clutch lever */

2009-10-30T23:19:31Z

Clutch lever

← Older revision		Revision as of 19:19, 30 October 2009
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	====Clutch lever====		====Clutch lever====

	Before you start, make sure to take careful notice of how the [[Cleaning and servicing the clutch switch\|clutch safety switch]] is installed. If you mess it up on the reinstall, it may be a while before you ride again. ~~The~~ plunger is the ~~delicate part~~.		Before you start, make sure to take careful notice of how the [[Cleaning and servicing the clutch switch\|clutch safety switch]] is installed. If you mess it up on the reinstall, it may be a while before you ride again. You have to make sure to not break off the plunger, which turns the switch on and off.

	[[Image:levers15aaa-2.JPG\|150px]]		[[Image:levers15aaa-3.JPG\|150px]]

	Loosen and unhook the clutch cable. [[Adjusting the clutch cable\|The adjuster]] should be all the way in. Loosen the adjuster at the handle bar by unscrewing the lock nut and turning the adjuster in to the clutch perch. Try to line up the slots in the adjuster and lock nut as shown to facilitate cable removal.		Loosen and unhook the clutch cable. [[Adjusting the clutch cable\|The adjuster]] should be all the way in. Loosen the adjuster at the handle bar by unscrewing the lock nut and turning the adjuster in to the clutch perch. Try to line up the slots in the adjuster and lock nut as shown to facilitate cable removal.

Bokonon: /* Clutch lever */

2009-10-30T23:12:14Z

Clutch lever

← Older revision		Revision as of 19:12, 30 October 2009
Line 9:		Line 9:
	====Clutch lever====		====Clutch lever====

	Before you start, make sure to take careful notice of how the [[Cleaning and servicing the clutch switch\|clutch safety switch]] is installed. If you mess it up on the reinstall, it may be a while before you ride again.		Before you start, make sure to take careful notice of how the [[Cleaning and servicing the clutch switch\|clutch safety switch]] is installed. If you mess it up on the reinstall, it may be a while before you ride again. The plunger is the delicate part.

			[[Image:levers15aaa-2.JPG\|150px]]

	Loosen and unhook the clutch cable. [[Adjusting the clutch cable\|The adjuster]] should be all the way in. Loosen the adjuster at the handle bar by unscrewing the lock nut and turning the adjuster in to the clutch perch. Try to line up the slots in the adjuster and lock nut as shown to facilitate cable removal.		Loosen and unhook the clutch cable. [[Adjusting the clutch cable\|The adjuster]] should be all the way in. Loosen the adjuster at the handle bar by unscrewing the lock nut and turning the adjuster in to the clutch perch. Try to line up the slots in the adjuster and lock nut as shown to facilitate cable removal.

Bokonon: /* Clutch lever */

2009-10-30T22:57:58Z

Clutch lever

← Older revision		Revision as of 18:57, 30 October 2009
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	[[Image:levers7-2.JPG\|150px]]		[[Image:levers7-2.JPG\|150px]]

	Remove the lever. It may be tight, but once the bolt is removed, just pull it out. If you have trouble removing the lever, it may be that the choke/turn signal housing is preventing the lever from getting past it. The mount for the clutch lever is adjustable ~~up and down on the bar~~. A single bolt secures it. If the clutch lever mount and the choke/signal housing are too close to each other on the handlebar, loosen that mounting bolt slightly and wiggle the clutch lever mount slightly farther toward the center of the bike.		Remove the lever. It may be tight, but once the bolt is removed, just pull it out. If you have trouble removing the lever, it may be that the choke/turn signal housing is preventing the lever from getting past it. The mount for the clutch lever is adjustable. A single bolt secures it. If the clutch lever mount and the choke/signal housing are too close to each other on the handlebar, loosen that mounting bolt slightly and wiggle the clutch lever mount slightly farther toward the center of the bike.

	~~Install~~ the ~~new cable, pushing~~ the ~~cable end~~ up ~~into the slot, and pulling~~ the ~~cable into the adjuster.~~		Reinstalling is these steps backwards. Make sure you don't break the switch on the reinstall. It should be lined up. The plunger is the delicate part.

	~~[[Image:19inlever~~.~~jpg\|170px]]~~

	~~The cable should look like this when installed correctly~~.		[[Image:levers15aaa-2.JPG\|150px]]
			[[image:13adjuster2- annotate.jpg\|150px]]

	~~[[Image:20inlever2~~.~~jpg\|170px]]~~		The plunger is pushed by the flat piece on the lever.

	~~Reinstalling is these steps backwards. Make sure you don't break the switch on the reinstall. It should be lined up. The plunger is the delicate part~~.		[[Image:levers16-2.JPG\|150px]]

	~~[[Image:levers15aaa-2~~.~~JPG\|150px]]~~		Install the cable, pushing the cable end up into the slot, and pulling the cable into the adjuster.

	~~The plunger is pushed by the flat piece on the lever~~.		[[Image:19inlever.jpg\|170px]]

	[[Image:~~levers16-2~~.~~JPG~~\|~~150px~~]]		The cable should look like this when installed correctly.

			[[Image:20inlever2.jpg\|170px]]

	====Front brake lever====		====Front brake lever====

Bokonon: /* Clutch lever */

2009-10-30T22:39:53Z

Clutch lever

← Older revision		Revision as of 18:39, 30 October 2009
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	[[Image:13adjuster2.jpg\|170px]]		[[Image:13adjuster2.jpg\|170px]]
	~~[[Image:levers3-2.JPG\|150px]]~~

	Now you can remove the old cable from the handle bar end. Pull the cable out of the adjuster screw, pulling away from the handle. Align the cable end with the slot, and pull the cable end down, out of the handle as shown.		Now you can remove the old cable from the handle bar end. Pull the cable out of the adjuster screw, pulling away from the handle. Align the cable end with the slot and pull the cable end down, out of the handle as shown.

	[[Image:18cableout.jpg\|170px]]		[[Image:18cableout.jpg\|170px]]
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	Remove the pivot bolt lock nut. Make sure you do the nut before you try to take the bolt out.		Remove the pivot bolt lock nut. Make sure you do the nut before you try to take the bolt out.

	[[Image:levers5-2.JPG\|150px]]		[[Image:levers5-3.JPG\|150px]]

	Remove the pivot bolt. You will need the ratchet to unscrew it.		Remove the pivot bolt. You will need the ratchet to unscrew it.

Bokonon: /* Clutch lever */

2009-10-30T22:32:36Z

Clutch lever

← Older revision		Revision as of 18:32, 30 October 2009
Line 14:		Line 14:

	[[Image:13adjuster2.jpg\|170px]]		[[Image:13adjuster2.jpg\|170px]]
	~~[[Image:levers2-2.JPG\|150px]]~~

	~~Line up the slots on the adjuster and the perch for the clutch cable to come out.~~
	[[Image:levers3-2.JPG\|150px]]		[[Image:levers3-2.JPG\|150px]]

	~~[[Image:levers4-2.JPG\|150px]]~~

	Now you can remove the old cable from the handle bar end. Pull the cable out of the adjuster screw, pulling away from the handle. Align the cable end with the slot, and pull the cable end down, out of the handle as shown.		Now you can remove the old cable from the handle bar end. Pull the cable out of the adjuster screw, pulling away from the handle. Align the cable end with the slot, and pull the cable end down, out of the handle as shown.

	[[Image:18cableout.jpg\|170px]]		[[Image:18cableout.jpg\|170px]]
			[[Image:levers4-2.JPG\|150px]]

	Remove the pivot bolt lock nut. Make sure you do the nut before you try to take the bolt out.		Remove the pivot bolt lock nut. Make sure you do the nut before you try to take the bolt out.
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	[[Image:levers7-2.JPG\|150px]]		[[Image:levers7-2.JPG\|150px]]

	Remove the lever. It may be tight, but once the bolt is removed, just pull it out. If you have trouble removing the lever, it may be that the choke/turn signal housing ~~kept~~ preventing the lever from getting past it~~. I actually disassembled that housing before I realized the real cause~~. The mount for the clutch lever is adjustable ~~- a~~ single bolt secures it. ~~The~~ clutch lever mount and the choke/signal housing ~~were~~ too close to each other on the handlebar, ~~by a couple of millimeters. I loosened~~ that mounting bolt slightly and ~~wiggled~~ the clutch lever mount slightly farther toward the center of the bike~~. Then everything fit just fine~~.		Remove the lever. It may be tight, but once the bolt is removed, just pull it out. If you have trouble removing the lever, it may be that the choke/turn signal housing is preventing the lever from getting past it. The mount for the clutch lever is adjustable up and down on the bar. A single bolt secures it. If the clutch lever mount and the choke/signal housing are too close to each other on the handlebar, loosen that mounting bolt slightly and wiggle the clutch lever mount slightly farther toward the center of the bike.

	Install the new cable, pushing the cable end up into the slot, and pulling the cable into the adjuster.		Install the new cable, pushing the cable end up into the slot, and pulling the cable into the adjuster.

Bokonon: /* Clutch lever */

2009-10-30T22:25:16Z

Clutch lever

← Older revision		Revision as of 18:25, 30 October 2009
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	[[Image:levers2-2.JPG\|150px]]		[[Image:levers2-2.JPG\|150px]]

	Line up the slots on the adjuster and the perch for the clutch cable to come out. ~~Carefully remove the old cable end from the clutch lever clevis, then pull the cable from the housing~~.		Line up the slots on the adjuster and the perch for the clutch cable to come out.
			[[Image:levers3-2.JPG\|150px]]

	[[Image:~~16leverout.jpg\|170px]]~~		[[Image:levers4-2.JPG\|150px]]
	~~[[Image:levers3~~-2.JPG\|150px]]

	~~Remove~~ the cable end.		Now you can remove the old cable from the handle bar end. Pull the cable out of the adjuster screw, pulling away from the handle. Align the cable end with the slot, and pull the cable end down, out of the handle as shown.

	[[Image:~~levers4-2~~.~~JPG~~\|~~150px~~]]		[[Image:18cableout.jpg\|170px]]

	Remove the pivot bolt lock nut. Make sure you do the nut before you try to take the bolt out.		Remove the pivot bolt lock nut. Make sure you do the nut before you try to take the bolt out.
Line 38:		Line 38:

	Remove the lever. It may be tight, but once the bolt is removed, just pull it out. If you have trouble removing the lever, it may be that the choke/turn signal housing kept preventing the lever from getting past it. I actually disassembled that housing before I realized the real cause. The mount for the clutch lever is adjustable - a single bolt secures it. The clutch lever mount and the choke/signal housing were too close to each other on the handlebar, by a couple of millimeters. I loosened that mounting bolt slightly and wiggled the clutch lever mount slightly farther toward the center of the bike. Then everything fit just fine.		Remove the lever. It may be tight, but once the bolt is removed, just pull it out. If you have trouble removing the lever, it may be that the choke/turn signal housing kept preventing the lever from getting past it. I actually disassembled that housing before I realized the real cause. The mount for the clutch lever is adjustable - a single bolt secures it. The clutch lever mount and the choke/signal housing were too close to each other on the handlebar, by a couple of millimeters. I loosened that mounting bolt slightly and wiggled the clutch lever mount slightly farther toward the center of the bike. Then everything fit just fine.

	Now you can remove the old cable from the handle bar end. Pull the cable out of the adjuster screw, pulling away from the handle. Align the cable end with the slot, and pull the cable end down, out of the handle as shown.

	~~[[Image:18cableout.jpg\|170px]]~~

	Install the new cable, pushing the cable end up into the slot, and pulling the cable into the adjuster.		Install the new cable, pushing the cable end up into the slot, and pulling the cable into the adjuster.

Bokonon: /* Clutch lever */

2009-10-30T22:19:21Z

Clutch lever

← Older revision		Revision as of 18:19, 30 October 2009
Line 11:		Line 11:
	Before you start, make sure to take careful notice of how the [[Cleaning and servicing the clutch switch\|clutch safety switch]] is installed. If you mess it up on the reinstall, it may be a while before you ride again.		Before you start, make sure to take careful notice of how the [[Cleaning and servicing the clutch switch\|clutch safety switch]] is installed. If you mess it up on the reinstall, it may be a while before you ride again.

	Loosen and unhook the clutch cable. [[Adjusting the clutch cable\|The adjuster]] should be all the way in.		Loosen and unhook the clutch cable. [[Adjusting the clutch cable\|The adjuster]] should be all the way in. Loosen the adjuster at the handle bar by unscrewing the lock nut and turning the adjuster in to the clutch perch. Try to line up the slots in the adjuster and lock nut as shown to facilitate cable removal.

			[[Image:13adjuster2.jpg\|170px]]
	[[Image:levers2-2.JPG\|150px]]		[[Image:levers2-2.JPG\|150px]]

	Line up the slots on the adjuster and the perch for the clutch cable to come out.		Line up the slots on the adjuster and the perch for the clutch cable to come out. Carefully remove the old cable end from the clutch lever clevis, then pull the cable from the housing.

			[[Image:16leverout.jpg\|170px]]
	[[Image:levers3-2.JPG\|150px]]		[[Image:levers3-2.JPG\|150px]]

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	[[Image:levers7-2.JPG\|150px]]		[[Image:levers7-2.JPG\|150px]]

	Remove the lever. It may be tight, but once the bolt is removed, just pull it out.		Remove the lever. It may be tight, but once the bolt is removed, just pull it out. If you have trouble removing the lever, it may be that the choke/turn signal housing kept preventing the lever from getting past it. I actually disassembled that housing before I realized the real cause. The mount for the clutch lever is adjustable - a single bolt secures it. The clutch lever mount and the choke/signal housing were too close to each other on the handlebar, by a couple of millimeters. I loosened that mounting bolt slightly and wiggled the clutch lever mount slightly farther toward the center of the bike. Then everything fit just fine.

			Now you can remove the old cable from the handle bar end. Pull the cable out of the adjuster screw, pulling away from the handle. Align the cable end with the slot, and pull the cable end down, out of the handle as shown.

			[[Image:18cableout.jpg\|170px]]

			Install the new cable, pushing the cable end up into the slot, and pulling the cable into the adjuster.

			[[Image:19inlever.jpg\|170px]]

			The cable should look like this when installed correctly.

			[[Image:20inlever2.jpg\|170px]]

	Reinstalling is these steps backwards. Make sure you don't break the switch on the reinstall. It should be lined up. The plunger is the delicate part.		Reinstalling is these steps backwards. Make sure you don't break the switch on the reinstall. It should be lined up. The plunger is the delicate part.

Bokonon: /* Front brake lever */

2009-10-30T22:09:55Z

Front brake lever

← Older revision		Revision as of 18:09, 30 October 2009
Line 49:		Line 49:
	Remove the pivot bolt lock nut from below, the same as on the clutch lever.		Remove the pivot bolt lock nut from below, the same as on the clutch lever.

	[[Image:levers9.JPG\|150px]]		[[Image:levers9-2.JPG\|150px]]

	Unscrew and remove the pivot bolt. This uses the flathead screwdriver.		Unscrew and remove the pivot bolt. This uses the flathead screwdriver.

	[[Image:levers10.JPG\|150px]] [[Image:levers11.JPG\|150px]]		[[Image:levers10-2.JPG\|150px]]
			[[Image:levers11-2.JPG\|150px]]

	Remove the lever.		Remove the lever.

	[[Image:levers12.JPG\|150px]]		[[Image:levers12-2.JPG\|150px]]

	To reinstall the brake lever just do these steps backwards.		To reinstall the brake lever just do these steps backwards.

	This job is very easy and quick to do.		This job is very easy and quick to do.