Grinding Off Clutch & Brake Levers - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 16 Old 05-12-2008, 01:24 PM Thread Starter
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Grinding Off Clutch & Brake Levers

Hello,

Well, I have some hand guards on order, that are the full wrap-around, Barkbuster type.

Of course I researched the lever length conflict after ordering. No big deal, I want these handguards bad enough to work through it.

I have read on some threads here where people grinded off some of the ball ends of the levers instead of replacing with shorter levers. My question is, instead of using a benchtop mounted wheel grinder, could I leave the levers on the bike and use a hand grinder, similar to the ones Makita sell (with the rotary disc grinder)?

I am just looking to make this as simple as possible. For me, even replacing levers can be a pain.

Thanks,
Jim
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post #2 of 16 Old 05-12-2008, 08:47 PM
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I will suggest removing the levers. Less chance of an oops to other parts. With the lever in a vise or clamped down you can have at er and make the job a lot easier to accomplish and add a more professional look to it.

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Last edited by water warrior; 05-18-2008 at 02:29 AM. Reason: bad spelling
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post #3 of 16 Old 05-12-2008, 10:24 PM Thread Starter
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I was starting to question myself how it would look just going to town sort of free-handed. Sometimes the quicker way isn't always the best way.
Thanks,
Jim
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post #4 of 16 Old 05-13-2008, 07:11 AM
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I would think you could do a nice job with a drummel. One hand holding the lever to stablize and the other using the tool.

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post #5 of 16 Old 05-13-2008, 08:07 AM
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I just used a cutoff wheel (oversized dremel). It was quick work. Don't hold on to the lever, it gets hot

-GW

GrayWolf
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post #6 of 16 Old 05-13-2008, 09:42 AM
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You can o what I did when I bent my brake lever.

Try bending with a vise and channel locks without first heating it up adequately. They're designed so ball and the last inch and a half or so break off very cleanly.

You're most welcome.

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post #7 of 16 Old 05-13-2008, 10:37 AM Thread Starter
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Thanks for all the info!
I have been wanting a reason to ad a hand-held grinder to my tool collection, as I have a couple of other projects going on I could use it on.
I will try the hand-held grinder. If it gets to squirrely, I will pull the levers and put them on the benchtop grinder.
Jim
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post #8 of 16 Old 05-13-2008, 01:20 PM
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There isn't any reason not to use a hand held grinder, so go ahead and buy one... but don't risk the damage to your bike (think of the grinder jumping off the lever and hitting the front fairing... ouch!!!$$$).

It takes aproximately 1 minute to remove the entire lever, and 2 minutes to replace them. Just don't lose the little round brass piece that touches piston of the clutch or brakes.

Also, you don't need to remove all the way to the brake off point. I recommend waiting until you have the barkbusters half installed and can see where you need to trim too.

This is an easy job... take no fear.

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post #9 of 16 Old 05-13-2008, 01:24 PM
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Quote:
Originally Posted by GrayWolf View Post
I just used a cutoff wheel (oversized dremel). It was quick work. Don't hold on to the lever, it gets hot

-GW
+1. I did the very same thing to my brake lever when installing aftermarket bars/guards. I only had to cut the ball off.

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post #10 of 16 Old 05-13-2008, 01:41 PM
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Since you have new knuckle guards just drop the damn thing. The ends of those levers break off cleanly, then just grind the sharp edges off.
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