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post #1 of 3 (permalink) Old 09-08-2012, 11:36 PM Thread Starter
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Brake and Clutch Lever Upgrades

Ok, so take this advise at your own risk....

The HD instructions on the edge cut brake and clutch levers says you need to bleed your brakes. Bull hockey! On the clutch lever, just unwind the clutch cable adjustment all the way and you'll be able to get enough cable play to remove the lever from the housing. Follow the service manual instructions for free-play after you replace the clutch lever - easy peasy. On the brake side, I suggest removing the switch housing and brake lever housing from the bars. This will free the brake light switch and master cylinder plunger. After you install the new lever, just be careful to place a spacer to give you some free-play between the brake switch and the lever as you re-install the brake lever housing and switch housing. You'll see how the brake switch engages the brake lever once you have it apart. Re-install the switch housing first on the brake lever side, and the shim the lever out a bit (5/32" or the width of a plastic tie strap) before you install the brake lever housing and seat onto the switch housing. Yes, you can screw-up the brake switch if you force it without a shim, but HMU if you get confused as you put it back together.
I think HD want to intimidate the backyard wrench, with their instructions, IMHO. You can do this, with basic tools. You don't need to bleed the brakes to install levers. Good grief. What next.....dump the trains fluid to adjust the clutch play?

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post #2 of 3 (permalink) Old 09-09-2012, 04:24 AM
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Also make sure you have a trained HD mechanic drain your blinker fluid.

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post #3 of 3 (permalink) Old 09-09-2012, 07:53 AM
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Originally Posted by gr8bigdude View Post
Ok, so take this advise at your own risk....

The HD instructions on the edge cut brake and clutch levers says you need to bleed your brakes. Bull hockey! On the clutch lever, just unwind the clutch cable adjustment all the way and you'll be able to get enough cable play to remove the lever from the housing. Follow the service manual instructions for free-play after you replace the clutch lever - easy peasy. On the brake side, I suggest removing the switch housing and brake lever housing from the bars. This will free the brake light switch and master cylinder plunger. After you install the new lever, just be careful to place a spacer to give you some free-play between the brake switch and the lever as you re-install the brake lever housing and switch housing. You'll see how the brake switch engages the brake lever once you have it apart. Re-install the switch housing first on the brake lever side, and the shim the lever out a bit (5/32" or the width of a plastic tie strap) before you install the brake lever housing and seat onto the switch housing. Yes, you can screw-up the brake switch if you force it without a shim, but HMU if you get confused as you put it back together.
I think HD want to intimidate the backyard wrench, with their instructions, IMHO. You can do this, with basic tools. You don't need to bleed the brakes to install levers. Good grief. What next.....dump the trains fluid to adjust the clutch play?

Remember that not doing this properly can cause death or serious injury. The manual says so.
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