The service manual say's to install a 5/32" cardboard insert between the brake lever and lever bracket. This will just squirt brake fluid out when I remove the banjo fitting. Or do I not understand the directions? Any help? thanks again

 

this shim is to keep the brake light switch from breaking.

it is important that the shim be used or you'll be fiddling around trying to get a new switch in place


mike

 

what exactly ae you wanting to do? if you aren't taking the lever off, then you don't need to use the shim. like mike said, it is to keep from breaking the little tit on the brake light switch. break that, and your brake lights will not shut off.

 

As for the shim, the tit on a small ziptie where the end slips through and tightens works great for sticking in there.

 

Need to replace the cable. If I'm not removing the lever I don't need the shim?

 

If you're not unbolting the master cylinder assembly from the handlebars you don't need the shim. If you're just changing the brake line and nothing else, you're fine.

If you are moving the master cylinder, controls, grips, etc from one set of handlebars to another, you have to put the shim in there.

 

Wow...I don't think I would have looked at the manual to remove stuff from bars (cuz I never did before) without seeing this post. I would have never thought a shim would be needed...I never saw a directive like that before. Now ya got me looking at everything.... Didn't think a bar change was this involved.

Supposed to remove a fuse too....anyone NOT remove the maxi-fuse when doing bars? I would never have removed a fuse either but book says to....which means you take off a bag to get into side panel...WTF....I have to remove bags to change bars now....this is crazy I tell you.

 

I changed out my grips this past weekend. I had the cardboard shim in and put everything back together. I decided that I didn't like how it went back together so I took the master cylinder/braker lever off again without the cardboard shim. (I forgot). When I put it back together....yep broke the plastic tit off. However, my break light does not stay on and everything is working correctly. I have the BAL-1 taillight and turn-signals running/break ligths plug and play module.