Seems near impossible to get the cotter pin out without removing the front header.

Or am I missing something obvious?

 

idk how the touring varies from my softail but i know it was a pita to get the cotter pin out and back in but possible

 

it can be done i did it a few weeks ago when i was taking it off to get powder coated. you just have to be prepared to loose some skin.

 

Long nose needle nose pliers. Beleive I loosened the rear master cylinder as well. PIA job.

 

x2. If I knew it was so difficult to get to it, I would have changed the brake lever when I did my header.

I got it replaced without removing the exhaust, but I had to walk away a few times. It helped mine was on a jack so I could lie on my back and use long needle nose pliers on the cotter pin.

 

I remember the cotter pin and small washer being a pain, but doable with long needle nose pliers. Takes allot of patience!

 

Keith ... There was a thread regarding this earlier this winter if I remember correctly.

 

Long nose needle nose pliers. Beleive I loosened the rear master cylinder as well. PIA job.

 

I think the same with me the skin/blood was the hard part.

 

Brake pedal, not brake lever. And yes, that darn thing is a bitch, even on a new bike. Wear gloves.