Installing new clutch & Brake levers
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Seasoned HDF Member
Joined: Jul 2009
Posts: 5,023
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From: Virginia
Installing new clutch & Brake levers
I thought tomorrow I would go and buy a set of chrome levers for the clutch and brake. Tonight I am reading through the service manual and see a 5/32 cardboard insert for the brake lever. Do these come as part of the lever package or do I need to buy it separately?
I didn't see anything that seemed difficult about the clutch lever install, did I miss it or is it that easy?
This is the first time I am going to do this and don't want to leave the bike unable to be ridden, I am not very mechanically minded. I have a set of retaining ring pliers will I need anything else?
I didn't see anything that seemed difficult about the clutch lever install, did I miss it or is it that easy?
This is the first time I am going to do this and don't want to leave the bike unable to be ridden, I am not very mechanically minded. I have a set of retaining ring pliers will I need anything else?
Outstanding HDF Member
Joined: Aug 2009
Posts: 2,729
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From: Republic of Texas
You just have to be careful when changing out the levers because of the brake light switch on the right side. I am sure your bike also has a clutch safety switch on the left side. These switches are easily damaged if care is not taken.
You can just use a standard piece of cardboard. I swapped mine out and didn't even know to be careful of the switch, and didn't have any issues at all. Just be easy on them, and be mindful if they snag on something don't just pull harder.
Ultimate HDF Member
Joined: Oct 2011
Posts: 5,691
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From: Olean, NY
If you look at the brake lever when you buy it or remove your current one, you'll see the protrusion that presses on the brake light switch. When installing the lever, many people snap off the switch with this part of the lever. The cardboard just keeps the protrusion from tearing the rubber boot and breaking the switch. This is what the switch looks like:
Ultimate HDF Member
Joined: Nov 2007
Posts: 6,975
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From: NJ
Just swapping out levers should be a piece of cake. I've had the clutch lever off but not the brake. FAIK, the piece of cardboard is only used when you're disconnecting the switch controls from the brake lever. It's keeps the lever open a tad to prevent damage to the brake light switch under the lever. But if you're removing the lever I don't see how the use of the cardboard shim would be applicable. Maybe someone else can give a more definitive response.
Seasoned HDF Member
Joined: Mar 2012
Posts: 100,455
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From: Centennial, CO
Piece of cake! Cut a piece off a heavy cardboard box same width as the lever and about an inch long. Squeeze the brake lever and stick the cardboard in there. Just be gentle, it's really pretty easy. Never did it B4 I did it. Should take less than an hour if you take your time. Have fun! This is one of the fun parts of ownership. Learning new stuff about your machine and YOU!
Ultimate HDF Member
Joined: Nov 2007
Posts: 6,975
Likes: 12
From: NJ
Piece of cake! Cut a piece off a heavy cardboard box same width as the lever and about an inch long. Squeeze the brake lever and stick the cardboard in there. Just be gentle, it's really pretty easy. Never did it B4 I did it. Should take less than an hour if you take your time. Have fun! This is one of the fun parts of ownership. Learning new stuff about your machine and YOU!
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Seasoned HDF Member
Joined: Mar 2012
Posts: 100,455
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From: Centennial, CO
Just to keep you from bangin the switch around. That's all. The switch itself is only held in there with a small V-shaped spring at least on my '04. Pretty fragile set-up.
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Joined: Sep 2006
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From: Rochester, NY
Way too many guys have discovered that the hard way, so if your ever messing around with the levers, take a minute to make and use the cardboard.
It'll save you some money and a whole bunch of aggravation.