V2 Enduro Lever Installation Instructions

Installation

1. Remove the stock lever. Remove the pivot bolt, clutch lever, and return spring.
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: push rod, pivot bushing, spacer, then thread into the pivot linkage.
4. Apply lubrication. Apply white lithium grease (or a similar lubricant) to the push rod, pivot bushing, pivot bolt, and all lever contact points.
5. Select your preferred clutch feel. Flip-chip technology allows directional installation to change lever feel. The closer the main pivot hole is to the linkage pivot, the softer the lever feels. The further away, the stiffer it feels.
   • 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 Braktec levers, casting variations between model years may cause a small amount of noise and friction when new. Ensure the 0.2 mm spacer is installed on the bottom of the lever, and apply grease liberally to all linkage and contact points. Any initial noise typically disappears after a couple of rides.
9. Set the perch position. Slide the lever perch inward as needed. Our levers are designed to be used at the hook, and the lever should not touch your middle finger when pulled with your index finger.

Adjustment

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 so 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.
• Make sure you have 1 to 2 mm of free play in the lever (when the bike is warm). Skipping this step may result in clutch slipping when the bike is hot, and in the worst case burning out the clutch.

Test and ride

• Ride under real conditions and evaluate clutch performance.
• Fine-tune the adjustment screw as needed.
• Flip the chip or swap to a different flip chip to fine tune your personal preference.

Tips

• Torque the master cylinder clamp bolts to 4 to 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.