M1100 Lever Install. Impossible?

[bobbydoll]

inspired by others' success on ebaying chinese knock off levers, i recently got myself a set. i'm trying to install them on my 2009 monster 1100 and ran into an issue. the new levers didn't come with new bushings, so i tried to remove and re-use the stock bushings from the original levers, but they seem impossible to remove. there isn't enough clearance to slide the barrel out. it seems the only way for me to remove them would be to cut them out using a hack saw. is there some trick to this that i'm not seeing?

i noticed that other 3rd party levers (rizoma, oberon) come bundled with their own bushings. this could be the root of the problem. guy from china didn't think of that, and didn't realize that the stock bushings are impossible to remove.

[DarkStaR]

That's what you get for buying cheap Chinese crap for your Italian bike.

Just make the beast with two backs'n with you.  

If you want to get the barrel out, you have to remove the pivot bushing to take the components fully apart.

(The pivot bushing is where the letter "i" in the text "this" overlaps the pic.)

My Pazzos came with a tool to remove the bushing.

[booger]

Can you wind the adjuster knob out all the way or remove it altogether to get the plunger/bushing out

[bobbydoll]

>>remove the pivot bushing...

you need a special tool for that. of course! haha. i tried banging with a screw driver inserted to no avail. grr!

removing the adjuster knob wouldn't have any effect.

if i don't get a response from the seller about this, i may just cut it out with a saw.

[DarkStaR]

Per the Pazzo instructions:

1) The brake lever bushing is tapped out from the bottom of the lever, and
2) The clutch lever bushing is tapped out from the top of the lever.

Don't know if it really makes a difference, but that's how I did it.

[jchurch]

On the 1100 the pivot is locked in place which is an annoying extra step. I had this issue when i installed my new Pazzo levers as well shortly after I brought the bike. At the time I ended up just cutting them out as the stock ones are worth like $20 and I planned to never use OR keep them anyways....... however after inspecting more closely after the rushed/eager installation I noticed that my Pazzo ones came with a special round like tool that was taped to the wall inside the box they came in and this tool slides in to allow them to 'unlock'..... ow well life lesson at the time

[xplodee]

Just press out the brass bushing and you're done. Use a socket that's the same outer diameter as the bushing and press it through with an arbor press or mallet.

[Punx Clever]

As many of the others have said, in nicer terms, you quite simply aren't clever enough.  Try harder meng! 

[bobbydoll]

@Punx congratulations! you've managed to successfully point out the obvious. wouldn't that be the main reason anyone would pose a help me type question to the board?

@DarkStaR you're right! the guy from china did come through in the end, but you beat him to the punch. he simply emailed a scan of the pazzo instructions. haha. when i tried tapping it out on the brake lever, i had only tried from the top. this is the trick i needed. thanks!

[DarkStaR]

 

[bobbydoll]

mission accomplished.