New Chrome Levers - spacing probs
Thread Starter
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Cruiser
Joined: Jul 2009
Posts: 208
Likes: 3
New Chrome Levers - spacing probs
So i went to the Long Beach, CA motorcycle swapmeet last weekend (any users go? it's awesome)... and got me some chrome brake and clutch levers for 25 bucks. nice.
installed em.. and started her up for sh*ts and giggles. well when I do a little rev'ing - the levers shake up & down like crazy - a little is expected, but they started making noise I could hear over the rev's.
They work fine - took it around the block - but what can I do to decrease the up & down movement. My previous (stock) levers didn't have as much ( though had some).. I've added some picks to show you the space difference. spacers? washers? SOL?
And lastly, this isn't a concern at the moment, but the thought came into my head while installing. How do I know if there is clutch slippage.. ie.. I install a new clutch lever and it just doensn't release the clutch 100% while I'm shifting, which over time will wear down the clutch components. How can I check for this.. Thanks in advance.
J.
btw, the pics aren't great.. but enough detail to show u the gap. and oh yeah, i'm holding the levers up or down in the pics - when i'm not the gap is on both top and bottom of the lever.. just holded the lever up so you could see the total gap.
installed em.. and started her up for sh*ts and giggles. well when I do a little rev'ing - the levers shake up & down like crazy - a little is expected, but they started making noise I could hear over the rev's.
They work fine - took it around the block - but what can I do to decrease the up & down movement. My previous (stock) levers didn't have as much ( though had some).. I've added some picks to show you the space difference. spacers? washers? SOL?
And lastly, this isn't a concern at the moment, but the thought came into my head while installing. How do I know if there is clutch slippage.. ie.. I install a new clutch lever and it just doensn't release the clutch 100% while I'm shifting, which over time will wear down the clutch components. How can I check for this.. Thanks in advance.
J.
btw, the pics aren't great.. but enough detail to show u the gap. and oh yeah, i'm holding the levers up or down in the pics - when i'm not the gap is on both top and bottom of the lever.. just holded the lever up so you could see the total gap.
Last edited by jousley; Jul 28, 2009 at 07:32 PM. Reason: more info
Road Master
Joined: Jan 2007
Posts: 971
Likes: 2
From: Mid USA
That is quite a bit more gap than mine have, can you re-arch the anti rattle clips or springs that are attached to the levers? See if you can add enough bend or arch to them to control the rattle, apply a light coat of lube to them on reassembly. (Are you sure that those are the correct levers for your bike?) On the second question, if you can feel the clutch latch up good when you let the clutch out and the rpm does not seem excessive for the amount power being applied or the speed that you are traveling at then it is probably ok. If you do not have the service manual get one, it is just about a necessity if you are going to do your own work.
picture
Here's a close up picture of the chrome clutch lever on my Dyna 2003. I cello-taped the ruler to the bracket to get both hands free to make this picture.
As you will notice, the upper side of the lever is fitting tight to the bracket; the gap at the bottom side (where the anti-rattle clip is situated) is a little over 1/16 of an inch. The clutch lever measures 11/16.
The CHROME CLUTCH BRACKET (45284-99D) as well as the CHROME HAND CONTROL LEVER KIT (45075-96) are genuine H-D parts.
When you search the H-D parts catalog, you will notice that there are different types of chrome hand control lever kits for different types of bikes.
My guess is that you bought the wrong type.
As you will notice, the upper side of the lever is fitting tight to the bracket; the gap at the bottom side (where the anti-rattle clip is situated) is a little over 1/16 of an inch. The clutch lever measures 11/16.
The CHROME CLUTCH BRACKET (45284-99D) as well as the CHROME HAND CONTROL LEVER KIT (45075-96) are genuine H-D parts.
When you search the H-D parts catalog, you will notice that there are different types of chrome hand control lever kits for different types of bikes.
My guess is that you bought the wrong type.
Thread Starter
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Cruiser
Joined: Jul 2009
Posts: 208
Likes: 3
I may have bought the wrong type. but I am sure i can get them to work. They function perfectionly (brake & clutch) - but looking for ideas to minimize the rattle. Perhaps a washer under the anti-rattle clips.. might try that this weekend.
Dude i have a crappy camera.
Was thinking about putting a shim in there. what do you suggest might stay? a rubber shim? or cloth material?
J.
Could you take pics that AREN'T out of focus?
Was thinking about putting a shim in there. what do you suggest might stay? a rubber shim? or cloth material?
J.
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J.,
I would suggest to put a spacer (plastic washer) around the hand lever pivot pin (see pic 1 part# 13) between the lower side of the clutch lever (#11) and the handlever bracket (#9) as well as between the anti rattle spring (#12) and the screw head (#18). Be carfull to manipulate the plastic anti rattle clamp and avoid breaking it!
Concerning the brake side: notice the caution warning (see pic 2) and be shure when you put in a spacer like described above, that the brake handlever pushes in the brake plunger into the brake cylinder in order to remain braking power!!
Please let us know the results!
René
I would suggest to put a spacer (plastic washer) around the hand lever pivot pin (see pic 1 part# 13) between the lower side of the clutch lever (#11) and the handlever bracket (#9) as well as between the anti rattle spring (#12) and the screw head (#18). Be carfull to manipulate the plastic anti rattle clamp and avoid breaking it!
Concerning the brake side: notice the caution warning (see pic 2) and be shure when you put in a spacer like described above, that the brake handlever pushes in the brake plunger into the brake cylinder in order to remain braking power!!
Please let us know the results!
René
Last edited by FXD2003Rider; Jul 29, 2009 at 04:38 PM.