Cardboard Insert For Brake Lever
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Intermediate
Joined: Oct 2009
Posts: 34
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From: FL Panhandle
Cardboard Insert For Brake Lever
I have an 09 Road King Classic. I am changing out handlebars and adding the Chrome Switch housings. Everywhere is a warning to put a cardboard insert between the brake leveer and the brake lever bracket (see attached picture) However, the end of my brake lever isn't flat like the picture but comes to a point. I see no way to put anything in there but don't want to break the switch. I called a local dealer and the service guy wasn't sure what I was talking about. Any help would be appreciated.
Tourer
Joined: Jan 2009
Posts: 325
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From: Tennessee
I just changed the bars on my 09 Ultra. If you can't get a piece of cardboard in there, yours is different than mine. I just pulled the brake lever to create some space and inserted a fairly thin piece of cardboard. It took a couple of trys to get it thick enough to hold the lever, but thin enought to fit in the space.
Extreme HDF Member
Joined: Apr 2006
Posts: 10,449
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From: Roswell, GA
jstride, if you look at the instructions for the HD chrome levers for '08 and up models, you'll see how to place the cardboard insert:
http://www.harley-davidson.com/en_US...ts/-J04278.pdf
The picture you posted is of the pre-'08 master cylinder/brake lever; the above link shows the '08 and newer m/c and brake lever.
Carl
http://www.harley-davidson.com/en_US...ts/-J04278.pdf
The picture you posted is of the pre-'08 master cylinder/brake lever; the above link shows the '08 and newer m/c and brake lever.
Carl
Advanced
Joined: Nov 2007
Posts: 71
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From: Kokomo, MS
Without that spacer in there holding the brake lever pulled, there is a very good chance of breaking the nipple off the brake light switch. then you've got to replace the brake light switch. That's a PIA job. Also depends on what year bike. HD changed the brake switch setup at some point in time, maybe mid 90's.
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Joined: Sep 2009
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From: Eastern NE
Grabbed small piece of cereal box from recycling to use on mine. If you pull brake lever - you don't see a gap where the switch button moves in/out??? Cardboard, or other slim protective item, is used to hold brake button & protect from snapping...