removing clutch and brake lever

cosmickites · June 12th, 2015, 10:17 AM

anyone know where i can locate info on how to remove the clutch side lever to replace with a short lever?

thank you

bigfoot · June 12th, 2015, 11:11 AM

Just release the slack on the cable adjuster then line up the slot so you can pull the cable out then undo the screw holding the lever to the bars. Job done. If you can get enough slack then undo the screw first and move the now loose lever to work the cable out of the slot.

BlueSwede · June 12th, 2015, 11:33 AM

+1.
And be sure to carefully grease the round nipple on the end of the clutch cable. If it doesn't rotate freely in the slot of the lever, it will snap the cable over time. Newer cables even come with a plastic cover on the nipple to help reduce friction...

On the brake lever side, be careful not to lose the very small round spacer that actuates the break light switch. It’s in the handle bracket housing and easily falls out, and can be tough to find on the ground.... I was lucky to spot it when I changed my levers...;-)

gatdammit · June 12th, 2015, 07:06 PM

And the brake lever spacer has a heavy grease on it from the factory. It looked petroleum based. I just used di-electric since it was open and looked similar.

cosmickites · June 13th, 2015, 02:49 AM

Brake lever spacer? Not sure I noticed one
Can I get a schematic or photo somewhere?

gatdammit · June 13th, 2015, 07:32 AM

It looks like a little elongated black plastic pill, maybe 1/8" diameter and 1/2" long. Rides in a pocket between brake lever plunger and bar mounted actuator. Very easily lost if you don't know to look for it.

cosmickites · June 13th, 2015, 02:02 PM

Ohh that. I tossed in trash. Didn't think I needed

Jk: luckily mine was stuck in old lever from so much Greece

Kindest

lomax · October 1st, 2015, 05:14 PM

I think I just did something bad and need your advice.

Front brake lever no problemo.

With the adjuster screwed all the way in there was just not enough play to pull the cable out. So like I have done on a hundred bikes before, I took my soft jaw pliers, compressed the clutch a little using the lever down at the housing, and took the clutch cable out of the bottom end.

When going to hook up the cable again at the bottom end now my clutch will not move hardly at all. It is like something inside the case got out of alignment or something.

Have I just screwed the pooch and will have to dive into the side cover or what.

Thanks.

Marc

BlueSwede · October 2nd, 2015, 03:19 AM

sounds a bit odd, since all you are doing is moving the clutch arm on the case manually, instead of by the cable. I can't really give any advice, because I don't know enough about this clutch and what could damage it...

June 12th, 2015, 10:17 AM	#1
cosmickites Member Joined: Jun 2015 From: long beach, New York Posts: 46	removing clutch and brake lever anyone know where i can locate info on how to remove the clutch side lever to replace with a short lever? thank you

June 12th, 2015, 11:11 AM	#2
bigfoot Member Joined: Feb 2015 From: Inverurie, Scotland Posts: 30	Just release the slack on the cable adjuster then line up the slot so you can pull the cable out then undo the screw holding the lever to the bars. Job done. If you can get enough slack then undo the screw first and move the now loose lever to work the cable out of the slot. Last edited by bigfoot; June 12th, 2015 at 11:16 PM.

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June 12th, 2015, 11:33 AM	#3
BlueSwede Senior Member Joined: May 2014 From: Charlottesville, VA Posts: 251 I Ride: 13 hyperstrada, montesa trials, selling Duc 900 SS CR	+1. And be sure to carefully grease the round nipple on the end of the clutch cable. If it doesn't rotate freely in the slot of the lever, it will snap the cable over time. Newer cables even come with a plastic cover on the nipple to help reduce friction... On the brake lever side, be careful not to lose the very small round spacer that actuates the break light switch. It’s in the handle bracket housing and easily falls out, and can be tough to find on the ground.... I was lucky to spot it when I changed my levers...;-)

June 12th, 2015, 07:06 PM	#4
gatdammit Senior Member Joined: Mar 2013 From: Naples, IT Posts: 1,959 I Ride: 2013 White Strada	And the brake lever spacer has a heavy grease on it from the factory. It looked petroleum based. I just used di-electric since it was open and looked similar.

June 13th, 2015, 02:49 AM	#5
cosmickites Member Joined: Jun 2015 From: long beach, New York Posts: 46	Brake lever spacer? Not sure I noticed one Can I get a schematic or photo somewhere?

June 13th, 2015, 07:32 AM	#6
gatdammit Senior Member Joined: Mar 2013 From: Naples, IT Posts: 1,959 I Ride: 2013 White Strada	It looks like a little elongated black plastic pill, maybe 1/8" diameter and 1/2" long. Rides in a pocket between brake lever plunger and bar mounted actuator. Very easily lost if you don't know to look for it.

June 13th, 2015, 02:02 PM	#7
cosmickites Member Joined: Jun 2015 From: long beach, New York Posts: 46	Ohh that. I tossed in trash. Didn't think I needed Jk: luckily mine was stuck in old lever from so much Greece Kindest

October 1st, 2015, 05:14 PM	#8
lomax Senior Member Joined: Sep 2015 From: Westminster, CO. Posts: 108	I think I just did something bad and need your advice. Front brake lever no problemo. With the adjuster screwed all the way in there was just not enough play to pull the cable out. So like I have done on a hundred bikes before, I took my soft jaw pliers, compressed the clutch a little using the lever down at the housing, and took the clutch cable out of the bottom end. When going to hook up the cable again at the bottom end now my clutch will not move hardly at all. It is like something inside the case got out of alignment or something. Have I just screwed the pooch and will have to dive into the side cover or what. Thanks. Marc

October 2nd, 2015, 03:19 AM	#9
BlueSwede Senior Member Joined: May 2014 From: Charlottesville, VA Posts: 251 I Ride: 13 hyperstrada, montesa trials, selling Duc 900 SS CR	sounds a bit odd, since all you are doing is moving the clutch arm on the case manually, instead of by the cable. I can't really give any advice, because I don't know enough about this clutch and what could damage it...