1. | See Figure 1. Insert new O-rings (3) on either side of the lever bushings. Install the new billet style brake lever (1) onto the shaft. | |
2. | Align the holes in the lever and brake rod and insert the stock clevis pin (B). | |
3. | Install the small saved flat washer onto the clevis pin. Insert the new cotter pin (2). | |
4. | Install the large flat washer (4) and locknut (5) from the kit. Secure locknut. Tighten. Torque: 20–27 N·m (15–20 ft-lbs) hex locknut | |
5. | Install the brake pedal pad to the brake lever. | |
WARNING Be sure the master cylinder relief port is not plugged. A plugged relief port can cause brake drag or lockup and loss of vehicle control, which could result in death or serious injury. (00317a) WARNING Contact with DOT 4 brake fluid can have serious health effects. Failure to wear proper skin and eye protection could result in death or serious injury.
NOTICE DOT 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239c) | ||
6. | NOTE A bulge may not be seen on models having remote reservoirs. a. Position motorcycle and handlebar so master cylinder is level (on some vehicles handlebar configurations the use of a flat jack may help position the vehicle). b. Remove the reservoir cover. c. Slowly actuate the brake lever while watching the surface of the brake fluid. A slight spurt of fluid will break the surface if internal components are working properly. d. Install the reservoir cover. See the service manual for proper torque specification. | |
WARNING Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a) | ||
7. | Check that the stop light goes on when the brake lever is actuated. | |
WARNING After repairing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a) | ||
8. | Test ride the motorcycle at low speed. |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | Brake lever assembly | Not Sold Separately |
2 | Cotter pin | 515 |
3 | O-ring (2) | 11900021 |
4 | Washer, 7/16 inch | 6416 |
5 | Locknut, 7/16 inch | 7825 |
Items mentioned in text, but not included in kit. | ||
A | Washer | |
B | Clevis pin | |
C | Inner O-ring |