1. | See Figure 1. Insert the new O-rings (4) on either side of the lever bushings (2). Install the new brake lever (1) onto the mounting shaft. NOTE There is insufficient clearance to install the clevis pin from the outside, so it must be installed from the inboard side of the brake lever. | |
2. | Align the holes in the lever and brake rod and insert the stock clevis pin (B) from the inboard side. | |
3. | Install the small flat washer (E) onto the clevis pin and insert the new cotter pin (5). | |
4. | Place the large flat washer (D) onto the brake lever mounting screw (A). Apply Loctite 243 (blue) to the threads of the screw, and install into the brake lever mounting shaft. Tighten the screw to 16.3–21.7 N·m (12–16 ft-lbs). | |
5. | Install the brake pedal pad (C) to the brake lever. | |
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) | ||
6. | Check the brake lever for proper operation and clearance through its full travel. |
Kit | Item | Description (Quantity) | Part Number |
---|---|---|---|
Kit 42677-05 | 1 | Brake lever assembly, includes items 2 and 3 | Not Sold Separately |
2 |
| 57217-02 | |
3 |
| 42644-00 | |
4 | O-ring (2) | 11364 | |
5 | Cotter pin | 515 | |
6 | Bushing (2), (not shown) | 42642-00 | |
Kit 40079-10 | 1 | Brake lever assembly, includes bushings | Not Sold Separately |
2 |
| 57217-02 | |
3 |
| 42644-00 | |
4 | O-ring (2) | 11364 | |
5 | Cotter pin | 515 | |
Items mentioned in text, but not included in kit: | |||
A | Screw | ||
B | Clevis pin | ||
C | Brake pedal pad, must be installed. Purchased separately | ||
D | Plain washer, type A | ||
E | Washer | ||
Some kits may require the use of original equipment hardware. |