🛠 V2 Enduro Clutch Lever — Installation and Setup Guide (Brembo & Braktec)

🔧 Installation Instructions

1. Remove the stock lever
   • Remove the pivot bolt, clutch lever, and return spring.
   • Note: The stock return spring is not reused. This lever uses a built-in adjustment screw instead.

   

2. Remove the stock plunger
   • Use pliers to remove the stock plunger.
   • The stock plunger is not reused.

   

3. Assemble the push rod

   For Brembo and Braktec clutches, assemble in this order:

   1. Push rod
   2. Pivot bushing
   3. Spacer
   4. Thread into pivot linkage

   

4. Apply lubrication

   Apply white lithium grease (or a similar lubricant) to:

   • Push rod
   • Pivot bushing
   • Pivot bolt
   • All lever contact points
5. Select your preferred clutch feel

   Flip-chip technology allows directional installation to change lever feel.

   

   • Brembo: Place the nylon spacer ABOVE the bushing.

     

   • Braktec: Place the metal spacer BELOW the lever.

     

6. Check push rod alignment
   • Ensure the clutch master cylinder push rod is straight, aligned, and fully seated before installing the new lever.
   • You may need to tighten the push-rod adjuster a few turns to ensure proper contact with the plunger.

   

7. Check spring alignment

   Ensure the free-play spring is correctly seated in the lever slot and fully engaged in the master cylinder housing.

   

8. Install the new lever
   • Reinstall the pivot bolt through the master cylinder housing and lever.
   • Tighten until snug - do not over-tighten.
   • After tightening, pull the lever to confirm smooth operation with no binding.
   • For Braketec clutch levers, due to casting variations between model years, a small amount of noise and friction may be present when the lever is new. Ensure the 0.2 mm spacer is installed on the bottom of the lever. Apply grease liberally to all linkage and contact points. Any initial noise will typically disappear after a couple of rides.

   

⚙️ Adjustment Instructions

Important: Only adjust the clutch once the bike has reached full operating temperature. Adjusting a cold clutch can cause clutch drag and inaccurate engagement, leading to excessive reach or clutch slippage.

Set the Engagement Point

• Use the adjustment screw to ensure the clutch fully disengages when the lever is pulled to the handlebar.
• Turning the screw clockwise moves the engagement point earlier in the lever pull.
• Adjust until the feel and engagement suit your preference.

Test and Ride

• Ride the bike under real conditions and evaluate clutch performance.
• Fine-tune the adjustment screw as needed
  
• Adjust flip the flip chip or use different flip chip to fine tune personal preference
  

🧰 Tips

• Torque the master cylinder clamp bolts to 4–6 Nm.
• Use plumber’s tape or friction tape under the clamp to help it rotate in a crash, protecting both the lever and the master cylinder.
• Recheck adjustments after a few rides.