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How To pull or swap your levers

Discussion in 'How-To' started by Gas Man, Jan 2, 2008.

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  1. Gas Man

    Gas Man Cool isn't cheap
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    For me, I had a scratched brake lever, for you, who knows. Something custom maybe...

    Remove the mirrors with the 1/2" hex head below the controls.

    LEFT SIDE

    Spray some lube down the top of the cover to help slide it up and out of the way.

    [​IMG]

    This is what you'll see

    [​IMG]


    Loosen the lock nut and spin the clutch cable loose

    [​IMG]

    Might as well lube the cable while you're here. Spray some lube in the hole. I do this many times to allow it to work down the cable.

    [​IMG]

    First Loosen the 1/8" allen controls set screw (like this right side pic)
    [​IMG]

    Remove the 2 - 3/16" allen screws from the front of the housing to seperate the housing.
    [​IMG]

    Seperate the housing like this
    [​IMG]
    [​IMG]

    Remove these 2 small allen head bolts and slide out that oval shaped retainer (that has the hole in it)
    [​IMG]

    Like so
    [​IMG]

    Now take a flat head screw driver and slide out the pin spacer where your mirror bolt use to be. You do this by pushing it out the bottom of the control. You will see a slot from the top to access the spacer in the control.

    It drops out this way
    [​IMG]

    Then you will be able to pull the lever out. (look at all that dirt... YIKES)
    [​IMG]
    [​IMG]

    Now simply push out the plastic dowel pin holding the clutch cable to the lever and poof
    [​IMG]

    Take this time to clean out the control and wipe everything clean. Might as well lube the clutch cable too.

    Then, simply put your new lever back on with that plastic dowel pin
    [​IMG]

    Then re-essemble this left side.
    [​IMG]

    And then of coarse tighten and adjust your clutch cable.
     
  2. Gas Man

    Gas Man Cool isn't cheap
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    RIGHT SIDE:

    Your mirror is already pulled.

    So now just like the left side...take a flat head screw driver and slide out the pin spacer where your mirror bolt use to be. You do this by pushing it out the bottom of the control. You will see a slot from the top to access the spacer in the control.

    It drops out this way (left side pick I know)
    [​IMG]

    Loosen the 1/8" controls set screw
    [​IMG]

    Seperate the controls with the 2 - 3/16" allens. You will now see the throttle cable farrels in the grip.
    [​IMG]

    Now keep the 3/16" allens and tool close by. If you need to leave, DO NOT leave controls hanging by the wires!!!! Simple spin the allens into the 2 control halfs and then leave. You can come back to the job and not damage anything.​

    Be sure to keep an eye on these... they are small and can fall off easily and be lost.
    [​IMG]
    [​IMG]

    Now you see this piece just in front of the handle bar in the shape of a pie. It needs to come out.
    [​IMG]

    Loosen and remove this allen bolt
    [​IMG]

    Now it will come out like so
    [​IMG]
    [​IMG]

    Pull the lever out and simply replace and re-assemble.

    [​IMG]
     
    francoblay1 likes this.
  3. Chopper Dave

    Chopper Dave SIICK!!!

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    Great post Gas!:up:
     
  4. Gas Man

    Gas Man Cool isn't cheap
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    Thanks. The benifit of only being able to spend a couple hours a day in the garage is being able to stay on top of these.
     
  5. kickstart

    kickstart Well-Known Member

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    Nice :up:
     
  6. slowrower

    slowrower 2007 Mastiff

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    I am going to go take mine apart just to lube the cables! thanks gas, great post. :2thumbs:
     
  7. Mickeetwo

    Mickeetwo Guru
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    Great post
     
  8. Gas Man

    Gas Man Cool isn't cheap
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    Thank you gents!
     
  9. V

    V Guru

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    Thank you sir
     
  10. TCALZ06

    TCALZ06 Well-Known Member

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    Remove these 2 small allen head bolts and slide out that oval shaped retainer (that has the hole in it)
    [​IMG]

    Like so
    [​IMG]



    Whats the trick to getting the oval shaped retainer out? I couldn't get it out when I bought my chrome hand controls. I just bought the chrome tribal levers so I want to do it myself this time.

    Thanks
     
  11. Raywood

    Raywood The Pirate
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    TCAL, it's a slotted horseshow type thing that retains the cable housing. I just stick a nail or small flat blade into the hole and wiggle it out. If your's is jammed you could probably stick a thin flat blade in from the cable side and push it up.

    :cheers:
     
  12. Gas Man

    Gas Man Cool isn't cheap
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    Yeah I just wiggled mine out or push it out with a screw driver...
     
  13. TCALZ06

    TCALZ06 Well-Known Member

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    Thanks guys

    Mine must have been jammed pretty good.
    I'll try with some more force tomorrow
     
  14. TCALZ06

    TCALZ06 Well-Known Member

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    jpg[/IMG]

    Now take a flat head screw driver and slide out the pin spacer where your mirror bolt use to be. You do this by pushing it out the bottom of the control. You will see a slot from the top to access the spacer in the control.

    It drops out this way
    [​IMG]

    Did you guys happen to notice if your pin spacer on the throttle side doesn't sit flush like the clutch side? mine is sticking out
     
  15. Gas Man

    Gas Man Cool isn't cheap
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    yep i think mine may have been like that.
     
    shovelshot likes this.
  16. alhall88

    alhall88 UAW

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    If you guys notice the horseshoe has a small 8-32 tapped hole in it. Just thread a small screw in there and pull it out.
     
  17. Gas Man

    Gas Man Cool isn't cheap
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    OH SNAP!!

    GO Al!!!!
     
  18. TCALZ06

    TCALZ06 Well-Known Member

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    Thanks guys!

    I put on the new BDM tribal levers
     
  19. Vegas

    Vegas Well-Known Member

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    I started installing my clutch cable tonight and my clutch lever sleeve was stuck like a mo fo. I ended up using an easy out type deal and just getting enough bite on it to spin it and work it loose.
     
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