How do I replace a clutch lever?

robartlum · June 16, 2008, 01:56:31 PM

My new clutch lever came in today but I dont have a clue as how to put it on.

Yeah I'm a newb rider and not very mechanically inclined although I am learning fast.

I know you guys are awesome with this kind of stuff and I would really appreciate it if anyone can give me some DETAILED instructions as how to go about doing this. Once I get it on, I ride.

ducpainter · June 16, 2008, 02:18:53 PM

Quote from: robartlum on June 16, 2008, 01:56:31 PM
My new clutch lever came in today but I dont have a clue as how to put it on. Yeah I'm a newb rider and not very mechanically inclined although I am learning fast.

I know you guys are awesome with this kind of stuff and I would really appreciate it if anyone can give me some DETAILED instructions as how to go about doing this. Once I get it on, I ride.

Do you have coffin style or goldline masters?

robartlum · June 16, 2008, 06:04:26 PM

Not sure. I just have the stock levers.

ducpainter · June 16, 2008, 06:15:12 PM

Quote from: robartlum on June 16, 2008, 06:04:26 PM
Not sure. I just have the stock levers.

Are the masters black or gold?

It kinda makes a difference.

Basically there is either a 12mm nut or one somewhat larger that holds the pivot bolt in place

robartlum · June 17, 2008, 05:25:40 AM

I have clutch levers with a hollow hole with a 12mm nut.

CDawg · June 17, 2008, 06:13:25 AM

I found these helpful when I replace my levers.
http://www.youtube.com/watch?v=cydSYQF8WhE&feature=related
http://www.youtube.com/watch?v=MTcBDi8-7AY&feature=related

DuciD03 · June 17, 2008, 10:22:14 AM

Photo's above arn't showing ....?

Sounds likre you have the standard stock levers; all balck coffin style masters (fluid resivoirs); its easy take your time and be patient and don't lose parts (I have an empty clean margarine container for parts as the come off; on complex jobs I have several with painters tape and a black marker where I'm numbering bolts and parts as there comming off ....) ;

remove the 12 mm nut; tap out the hollow bolt; carefull not to damage the bolt threads (ide thread the nut to the bottom of the bolt leave the nut on untill you've tapped that almost out to protect the threads). There will be a bit of tension on the lever and the bolt as the clutch master metal nub (for lack of better words) will be pushing on the lever; so tap out the bolt and carefull to not damage or remove the nub as the bolt comes out .... install in revers order; you'll have to be patient to press in the nub with the lever and slide the bolt through and tighten the bolt; check the lever to see that its working properly and doesn't need adjustment (it shouldn't).

Spider · July 18, 2008, 04:50:09 AM

that top video was fantastic Cdawg! great find

My brake lever was easily done....

I'm stuck on the clutch (Brembo Goldline) the 1.5mm (video states 2mm) hex grub nut won't budge - so i'm stuck at the moment!

One Lever Spider

jjimmyp · July 18, 2008, 11:27:38 AM

You know of a video by chance that shows how to change the clutch lever when you have the round master cylinders and adjustable levers? (2001 900) - there's that pivot piece which seems to be a pain to get out. Some guy wrote me a great explanation on here, but a video would be helpful. Thanks!

Quote from: CDawg on June 17, 2008, 06:13:25 AM
I found these helpful when I replace my levers.
http://www.youtube.com/watch?v=cydSYQF8WhE&feature=related
http://www.youtube.com/watch?v=MTcBDi8-7AY&feature=related

CDawg · July 18, 2008, 11:42:53 AM

Quote from: jjimmyp on July 18, 2008, 11:27:38 AM
You know of a video by chance that shows how to change the clutch lever when you have the round master cylinders and adjustable levers? (2001 900) - there's that pivot piece which seems to be a pain to get out. Some guy wrote me a great explanation on here, but a video would be helpful. Thanks!

What do you mean by the pivot piece? I had a pretty straight forward time when I replace both levels (adjustable w/ cylindrical resevoirs). Are you refering to the tiny hex set screw that is fixed to the plunger rod?

jjimmyp · July 18, 2008, 11:48:57 AM

There's a piece that is on the lever that I have to take off and attach to the new lever. Can't seem to figure out how it comes off without breaking it. Is there a screw somewhere I'm missing? thank you

Hedgehog · July 18, 2008, 11:56:40 AM

It would help if you posted a picture of exactly what you're talking about, or refer to ducati.com's parts catalog by page number and part number. Or even linked in some other page with a picture of the piece you're trying to move. The word "piece" by itself isn't very descriptive.

CDawg · July 18, 2008, 01:08:24 PM

Quote from: jjimmyp on July 18, 2008, 11:48:57 AM
There's a piece that is on the lever that I have to take off and attach to the new lever. Can't seem to figure out how it comes off without breaking it. Is there a screw somewhere I'm missing? thank you

You are refering to the infamous set screw. If you look carefully (on the bottom I think) you should find some hardened glue like substance. You need to carefully pry away some of the glue (maybe with heat first) to uncover a hex screw. It is the smallest allen wrench you will need to remove this screw. Be very careful as it strips easily and you cannot buy just the screw from Ducati. Luck for me, my ASV levers doesn't re-use that part. The next challenge you will face is pushing the rod back into the plunger. I found lube and pinching the plumger to work well.

Spider · July 18, 2008, 03:18:44 PM

yep, that is the hex screw I'm having trouble getting out!

JJimmy, looking at the assembly on the underside (when installed on bike) there is a tiny grub screw, use a 1.5mm allen key to loosen it, then use a small 3mm standard screwdriver to undo the plunger rod (measure distance before hand).

reassemble the parts inside new lever.

grease the rubber port or the plunger and away you go!

jjimmyp · July 18, 2008, 06:04:35 PM

ahh, those damn set screws.

thank you

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How do I replace a clutch lever?