Swapping levers
Thread Starter
|
Outstanding HDF Member
Joined: Mar 2007
Posts: 2,360
Likes: 3
From: Naalehu, Hawaii
Swapping levers
I saw a post by Bluerose abouta stoplamp switch problem she had which enlightened me to new additional information I couldn't locate in my service manual nor see the part in my parts book. I am planning to swap out my brake & clutch levers for black powdercoated levers and am learning there is a V shaped wedge that goes between the switch and the housing.
Will I need to disassemble the right housing to change out the levers? Or is it as simple as removing the retaining ring, pulling the pivot pin and reassembling it with the new lever?If its in the service manual I didn't see it. I'm okay on the clutch side, but I don't want to damage the brake lamp switch on the right.
Any input would be appreciated.
Arvid
Will I need to disassemble the right housing to change out the levers? Or is it as simple as removing the retaining ring, pulling the pivot pin and reassembling it with the new lever?If its in the service manual I didn't see it. I'm okay on the clutch side, but I don't want to damage the brake lamp switch on the right.
Any input would be appreciated.
Arvid
Road Master
Joined: Jun 2006
Posts: 783
Likes: 1
From:
RE: Swapping levers
In the service manual it says to use a small pice of cardboard before installing the new lever. I did this and it worked good, I was warned buy a friend that did not do this and had to repace the switch because it broke. Place the cardboard up against the switch during placement of the lever then remove it.
Seasoned HDF Member
Joined: Feb 2007
Posts: 10,602
Likes: 721
From: Bellevue, NE
RE: Swapping levers
The "V shaped wedge" that you're talking about is probably the spring that applies pressure to the brake light switch. When you disassemble the right side housing you can see it by looking at the back side of the switch. It just sits in there and could get lost if you're not careful.
Keep in mind that the clutch side housing on your '07 also has a clutch safety switch that looks just like the brake switch. It's possible to break that one too if you're not careful.
Keep in mind that the clutch side housing on your '07 also has a clutch safety switch that looks just like the brake switch. It's possible to break that one too if you're not careful.
Outstanding HDF Member
Joined: May 2006
Posts: 2,378
Likes: 1
From: Boise, Idaho
RE: Swapping levers
Also be sure you are using levers for '07 and newer. the clutch lever has an additional little bump on it that pushes against the clutch switch. the earlier models don't have this bump on the lever. if you use the wrong lever, you can't start it unless you are in neutral.
don't ask me how i found out.
don't ask me how i found out.
Extreme HDF Member
Joined: Apr 2006
Posts: 10,449
Likes: 46
From: Roswell, GA
RE: Swapping levers
ORIGINAL: Arvid
I saw a post by Bluerose abouta stoplamp switch problem she had which enlightened me to new additional information I couldn't locate in my service manual nor see the part in my parts book. I am planning to swap out my brake & clutch levers for black powdercoated levers and am learning there is a V shaped wedge that goes between the switch and the housing.
I saw a post by Bluerose abouta stoplamp switch problem she had which enlightened me to new additional information I couldn't locate in my service manual nor see the part in my parts book. I am planning to swap out my brake & clutch levers for black powdercoated levers and am learning there is a V shaped wedge that goes between the switch and the housing.
What service manual do you have????
Trending Topics
Thread Starter
|
Outstanding HDF Member
Joined: Mar 2007
Posts: 2,360
Likes: 3
From: Naalehu, Hawaii
RE: Swapping levers
Okay, the front brake master cylinder in section 2 shows a better exploded parts view, and it even talks about the front stoplight switch p/n 00324a, but doesn't show the electrical stop switchin the exploded parts view.
In Bluerose's thread https://www.hdforums.com/m_3159732/tm.htm"Streeter" states ... Yes, there is a brass or copper V shaped wedge that fits between the switch and the housing (07). Also check and make sure the the small tip of the switch didn't get broken during your bar swap. Good luck
I'm not making reference to physicallyinserting a wedge of cardboard in between the lever and the bracket, I want to see the electrical switch and the copper V shim(Comfortably Numb refers to it). At the end of her thread Bluerose said the V wedge was still there, it just got squished, they widened it back out and put it back in, problem solved.
Unless theres something I'm missing completely, I want info on the electrical stop lamp switch, thats what I can't find. My service manual is 2007 Touring Models, p/n 99483-07. For the front stoplight switch in section 8, it says to see section 8.22 Handlebar switches, switch repair/replacement, it does not show the switch, it just cautions you not to damage it.
Arvid
In Bluerose's thread https://www.hdforums.com/m_3159732/tm.htm"Streeter" states ... Yes, there is a brass or copper V shaped wedge that fits between the switch and the housing (07). Also check and make sure the the small tip of the switch didn't get broken during your bar swap. Good luck
I'm not making reference to physicallyinserting a wedge of cardboard in between the lever and the bracket, I want to see the electrical switch and the copper V shim(Comfortably Numb refers to it). At the end of her thread Bluerose said the V wedge was still there, it just got squished, they widened it back out and put it back in, problem solved.
Unless theres something I'm missing completely, I want info on the electrical stop lamp switch, thats what I can't find. My service manual is 2007 Touring Models, p/n 99483-07. For the front stoplight switch in section 8, it says to see section 8.22 Handlebar switches, switch repair/replacement, it does not show the switch, it just cautions you not to damage it.
Arvid
HD Forum Stories
The Best of Harley-Davidson for Lifelong Riders
7 Surprising Harley-Davidson Products that Are Not Motorcycles
Verdad Gallardo
8 Best Harley-Davidson Motorcycles Ever
Pouria Savadkouei
10 Worst Harley-Davidson Motorcycles Ever
Pouria Savadkouei
Killer Custom's Jail Break Is The Breakout That Refused to Blend In
Verdad Gallardo
Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?
Verdad Gallardo
Harley-Davidson Reveals Super Cool Cafe Racer Concept
Verdad Gallardo
Engraved Rebellion: Inside Bundnerbike's Glam Rock II
Verdad Gallardo
10 Motorcycles You Should Never Buy
Joe Kucinski
10 Things Harley-Davidson Needs to Fix in 2026
Verdad Gallardo
Road Captain
Joined: Oct 2007
Posts: 715
Likes: 2
From: NW Florida
RE: Swapping levers
Inserting the wedge as everyone is suggesting is to prevent damage to the rubber boot and the switch plunger. The wedge is supposed to be placed between the lever and the switch housing. In your case it isn't going to do any good because as soon as you pull the pin to replace the lever that little wedge is going to be on the floor. Just try pulling the pin and carefully removing and reinstalling the new lever. Can't find anything in the manual about replacing levers.
Outstanding HDF Member
Joined: Mar 2005
Posts: 2,007
Likes: 4
From: Vancouver, B.C.
RE: Swapping levers
I'm not making reference to physicallyinserting a wedge of cardboard in between the lever and the bracket, I want to see the electrical switch and the copper V shim(Comfortably Numb refers to it).
All you'll want to do is push the switch tip in and hold it there by taping a piece of cardboard in place between the end of the lever that activates it and the switch housing to keep it out of the way to avoid breaking it off.
CN