Replacing an adjustable lever

[jjimmyp]

Hi guys - anyone know how to get off (and on the new lever) that pivot piece that is on an adjustable lever? i can't figure out how to get it off w/o breaking it entirely.  this is the piece that attaches to a new adjustable lever, as my bike went down and need to swap it.  thanks!

[clubhousemotorsports]

first off which lever clutch or brake?
which master gold line?
coffin?
radial?

[jjimmyp]

Sorry - its an '01 900 so it came with the radial reservoirs, on the clutch side. this is the OEM lever.  Thanks!

[clubhousemotorsports]

Okay so you have a  non-radial master with remote resevoirs, solid pin.

take a 10mm wrench and loosen the nut under the lever, this is on the bottom of the flat blade screw. The nut is a lock nut so remove it first and then unscrew the pivot bolt (flat blade screw on top), there will be a little pressure on the lever from the hydraulics but nothing will come out. remove the lever carefull not to loose the gold pin the lever pushes into the master.

reassemble in the opposite direction and be sure to snug the pivot bolt and tighten the lock bolt. make sure the lever has no drag and returns easily with no drag. If it has drag you have the pivot bolt too tight.

the clutch should work now but there is one last step. make sure you have a little free play in the lever about 1/8 "-1/4" if the lever needs adjusting there is a flat blade screw in the end of the lever pivot mechanism, in reduces freeplay out adds freeplay. if you are too far in the clutch may slip. out too far and neutral will be hard to get with the bike running at a standstill.
good luck

[jjimmyp]

great - thanks so much!