Lever Maintenance
by Andrew Strafford
Don’t neglect your levers, for smooth and reliable operation of clutch and front brake levers take them apart occasionally and clean and lube.
You will need
Light, daylight, bench light, garage light, working light or head band light or all of them
2 x 10 mm spanners
Small Philips head screwdriver
WD-40 or similar (fuel if you have pyromaniacal inclinations)
Marine grade lithium based grease (I am sure there are many other suitable and possibly superior lubes)
Thread lock or similar
Rags
Cigar (nicotine aids concentration)
Cover front guard and tank etc with sheet to avoid scratches and oil contamination
If the bike is on the side stand then bars all the way to the right to work on the Clutch lever and all the way to the left for the Brake lever, just makes things easier to get at and see
Clutch Lever
Remove 2 small Philips head screws holding clutch lockout switch to bottom of lever mount, clean switch with spray of WD-40 and wipe with rag, and leave hanging under lever
Remove lever mounting screw with 10mm spanners and remove lever (keep your spare hand under the lever as it is withdrawn in case the pivot or pushrod falls out), the pushrod rod is not attached to the lever but fits into a hole in the pivot and should stay in place in the dust seal. Clean mounting and contact areas on master cylinder thoroughly with WD-40 and rags, you will need small fingers or narrow blunt rod to get into all nooks and crannies, smear grease on all contact areas. Clean the lever, mounting bolt and pivot thoroughly with WD-40 and drag and then smear pivot with grease and refit to lever, smear grease over all contact areas of lever and refit to master cylinder, grease and replace bolt (I use a little thread lock on the nut just to be sure), replace clutch lockout switch, you may need to operate lever to get switch lined up with slot on lever, wipe all surfaces clean and check operation of clutch lever and switch (hopefully smooth as a baby’s). Move on to brake lever
Brake Lever
Remove lever mounting screw with 10mm spanners and remove lever. Clean mounting and contact areas on master cylinder, brake piston and dust seal and front brake switch thoroughly with WD-40 and rags, you will need small fingers or narrow blunt rod to get into all nooks and crannies, smear grease on all contact areas and some WD-40 on dust seal. Clean the lever and mounting bolt thoroughly with WD-40 and rag and then smear grease over all contact areas of lever and refit to master cylinder, grease and replace bolt (I use a little thread lock on the nut just to be sure), wipe all surfaces clean and check operation of brake lever and switch (hopefully smooth as a baby’s).
Clean up, tools away, test ride.