Clutch and Front Brake Levers RemovalThe front brake lever and clutch levers are usually only removed to replace them. Short aftermarket levers might stand less of a chance of breaking in a fall. I saw recently where short levers also may decrease the chance of certain finger injuries in a fall. I believe the main purpose of switching to aftermarket levers is appearance. The OEM levers are lighter in weight than Pazzos. I have not had the opportunity to weigh other brands of aftermarket levers.
10mm box end wrench
silicone spray lube
silicone grease or white lithium grease
nonpermanent thread locking agent
Unless otherwise noted, The following procedures for lever removal are identical for both the front brake lever and the clutch lever.
1. Use an 10mm box end wrench to remove the pivot bolt lock nut which is located under the lever perch.
2. Use an 8mm socket to remove the pivot bolt.
To unscrew and pull the pivot bolt smoothly, apply light pressure to the lever toward the inside of the perch, counteracting the outward pressure of the pushrod (clutch) or plunger switch (brake).
3. Remove the lever from the perch.
Be careful that the gold pushrod bushing does not drop out of the clutch lever.
The front brake lever does not have any loose parts installed to it.
4. Wash the grime from the perch with a rag moistened with silicone spray lube.
Use a cotton swab moistened with silicone spray lube to clean the metal push rod (clutch) and gold disc (front brake). Use a cotton swab to clean in the corners of the perch around the rubber dust boot. Avoid applying grease or lube of any kind to the small electronic plastic sensor with push switch to the inside of each lever perch.
5. Clean the pivot bolt and the bushing with silicone spray lube. Use a cotton swab to clean out the hole in the bushing.
6. Clean the silicone residue from the threads of the perch and the pivot bolt with denatured alcohol on a cotton swab.
7. Apply silicone or white lithium grease to the areas of the lever, perch, pivot, bushing (clutch lever) and plunger switch (front brake lever) where they contact one another.
The clutch lever
The front brake lever
the clutch lever pushrod bushing and inside the hole
...and the pivot shaft of the pivot bolt.
8. Install the pushrod bushing to the clutch lever. Place the lever into to the perch being sure the pushrod seats into the bushing hole. Hold pressure inward on the pushrod or plunger switch to align the perch and lever holes. Insert and thread in the the pivot smoothly.
10. Tighten the the pivot bolt just a bit more than finger tight (torque spec: pivot bolt, 1.8 ft pounds) with a 8mm socket.
11. The pivot bolt locknut has a nylock insert which is designed to prevent it from coming loose. If the lock nuts do not have the nylock insert, use nonpermanent thread locking agent. Tighten the pivot bolt locknut snug. (torque spec: pivot bolt, 4.5 ft pounds) with a 10mm box end wrench. Do not use thread locking agent with nylock nuts.
OEM levers: 8.60 oz (Clutch lever 4.25 oz, Front Brake lever 4.30 oz )
Pazzo Levers: 9.15 oz (clutch lever 4.60 oz, front brake lever 4.60 oz).
Net weight increase of .55 oz