This is a very simple job and can be done by anyone with simple tools. I installed ASV C/5 standard clutch and black levers, but this install will work for all aftermarket levers.
PURCHASE FROM RevZillia:
www.revzilla.com/motorcycle/asv-c5-sport-brake-lever-aprilia-honda-kawasaki-moto-guzzi-yamahawww.revzilla.com/motorcycle/asv-c5-sport-clutch-lever-aprilia-honda-suzuki-triumph-yamaha
TOOLS YOU'LL NEED:
1. Flat Head screwdriver
2. 1/4" socket wrench
3. Deep pocket 10mm socket (any 10mm will do, but if you don't use a deep pocket you'll have to remove the gauge pod on the clutch side to get to the clutch nut)
4. 2.5mm allen head wrench
5. 10mm box wrench
6. Needle Nose pliers
7. White lithium grease
BRAKE LEVER:
Step One:
Remove nut from underneath brake lever using 10mm box wrench (save it is small and can get lost)
Step Two:
Using flat head screwdriver remove the screw on top of the brake lever
Step Three:
Remove OEM brake lever and set aside
Step Four:
Take ASV Brake lever and get the medium bushing, taking the White Lithium Grease and coating bushing.
Insert bushing into brake lever arm open hole (it's the only hole it will fit in)
Step Five:
Take White Lithium Grease and coat the Flat Head Bolt
Step Six:
Look under the brake fluid reservoir and you will see a brake solenoid lever. Coat that with White Lithium Grease
Step Seven:
Take the new Brake Lever and insert it back in place making sure to fit the brake solenoid lever into the hole it lines up with (VERY IMPORTANT)
Step Eight:
Insert Flat Head Screw and screw until hand tight. Now take the nut and tighten to hand tight.
DONE!
Turn the bike on and squeeze the brake lever listening for a clicking sound of the solenoid. Then roll the bike back and forth checking for the front brake to function correctly.
CLUTCH LEVER: (this one takes a little bit more time)
Step One:
Take the 1/4" ratchet and 10mm deep pocket socket (if you don't use a 1/4" deep pocket socket you'll have to remove the control cluster to get at the bolt).
Remove the bolt from the bottom of the screw holding the clutch in place.
Step Two:
Remove the bolt that is holding the clutch lever in place. You will notice that the bolt is indexed to fit in to the notch so it won't rotate when you tighten it.
Step Three:
Remove the Clutch Lever. You will notice that it is attached to the clutch cable. Pull the lever towards you and twist until you see the locking pin attached to the cable. Slide the pin out of the clutch lever. The pin and cable will pull tight to the clutch cable adjustment wheel.
Step Four:
Screw the Neutral Kill Tab, using 2.5mm Allen Head Wrench, into place using a small amount of LOCTITE. Look at the OEM Clutch Lever and match the Beveled side to the same as OEM.
Step Five:
Apply White Lithium Grease to the Supplied Bushing (Or OEM if one is not provided) and re-insert into the new Clutch Lever.
Step Six:
Apply White Lithium Grease to the Clutch Bolt
Step Seven:
Just like when you removed the OEM Clutch Lever, turn the ASV Clutch Lever over so you can see the Clutch Cable Pin hole.
Take the Needle Nose Pliers and grab the Clutch Pin. Pull on the Clutch Pin so you get slack. If you need more slack adjust the Clutch Cable Adjustment Wheel to give you more slack.
Inset the Clutch Cable Pin into the hole on the ASV Clutch Lever.
Now spin the ASV lever over and re-inset into housing.
Step Eight:
Inset the Clutch Lever Bolt into and press fit making sure the index tab lines up so the bolt sits flat.
Step Nine:
Take the 1/4" wrench and 10mm deep pocket socket and tighten bolt to hand tight.
DONE!
Check to see that the clutch has tension and does not bind. Check to see if you feel the cable engaging the clutch. Now start the bike and slowly engage the clutch in first and check to see that the clutch in engaging and moving the bike forward. SLOWLY. Make any adjustment to the Clutch Cable Adjustment Wheel based on your preferences.
Test Cruise Control to see if ligh works. Test Clutch Neutral Shut off to see if it works.
Take the bike out and SLOWLY ride it checking the Clutch Engagements and Front Brake Engagements. Make sure it feels right and there is no binding and or 'weird feel'. If there is STOP and check your work.
After checking the fit, feel, and operations of the install, ENJOY YOUR NEW CLUTCH AND BRAKE LEVERS.
. Thanks. If nobody replies, I'll come back and comment on the installation, for future buyers.
