Clutch & brake lever replacement

[lewellen]

Hi, folks,

What might be a dumb question here...

When I went to try to replace my '08 R1200R's brake and clutch levers, I found I couldn't remove the pivot-and-plunger assembly from the old lever. The pivot and plunger need to be reused on the new lever, but the piece they ride in, does not. It looks like the plunger should unthread from the pivot, letting both be removed from the assembly, but I can't find a hex-hey that both fits and doesn't spin in the back of the plunger and I'm a tad reluctant to mash down on the plunger with a Vice-grips.

More frustratingly, when I check the service manual, the pivot-and-plunger assembly is clearly there; but neither the individual parts nor the assembly appear to be on the BMW parts fiche for the bike (e.g. http://www.ascycles.com/Illustrated_cat ... 2+Steering).

At this point I'd rather order new parts than risk messing up my old levers, but how can I do that if I can't find the parts to order? Thoughts? (The quasi-local dealer just went out of business; the next nearest dealer is ~100 miles away.)

Thanks much,

- Lewellen180

[mogu83]

lewellen -
Just a quick thought. I don't know of any place that BMW used hex keys on this bike (I could be wrong) most of the fasteners are torx (star) type. Surprised you don't have a set yet. Check to make sure your using the right kind. I think websterize just changed his levers but he's most likely at work.

[lewellen]

lewellen -
Just a quick thought. I don't know of any place that BMW used hex keys on this bike (I could be wrong) most of the fasteners are torx (star) type. Surprised you don't have a set yet. Check to make sure your using the right kind. I think websterize just changed his levers but he's most likely at work.

I do have a Torx set, just no bits small enough to go in there. :-)

Best,

- Lewellen180

[BigEasy]

Lewellen, It's been a couple of years since I replaced mine with Pazzo's but I don't remember it being real difficult. Maybe not totally intuitive. I tried to find the instructions that were supplied with my new levers and could not locate them. I also tried looking on the Pazzo website and they are not posted there. However, I bet if you called their tech support line they could e-mail you a PDF of the instructions. Worth a shot.

[websterize]

Heya, Lewellen, I changed out the black levers for BMW's milled levers, shown here …



That brass cylinder slides out. Harry is correct — the lever screw is Torx. The spring is for pushing the lever forward to adjust span. Check out the link under my sig for more install pics.