If your clutch or brake lever is getting some sloppy up and down movement then there's an easy, inexpensive way to fix it without having to buy a whole new lever. All K bike clutch levers and the brake levers on 4V Ks have a nylon sleeve in the lever that the pivot pin goes through. When these sleeves wear over time the hand levers can become sloppy. For some reason this is not the case for the 2V brake levers. Keeping that pivot lubed with bearing, lithium or moly grease is your best bet for keeping the pivot pin and lever from wearing.
Replacing the clutch lever sleeve:(see attached diagram below)
Clutch lever nylon sleeve (bush) part #: 32721451796
1 - Pull the clutch lever all of the way in and stick a piece of wood in between the exhaust and the clutch arm on the back of the transmission. This keeps the clutch arm up, making it easier to detach and reattach the end of the cable.
2 - Detach the clutch end of the cable from the clutch arm.
3 - Remove the clutch lever pivot pin using a regular screwdriver on the top and an open-ended 10mm box wrench on the bottom of it. Once the nut is off it comes out from the top.
4 - With the other end of the cable detached there should be enough slack in the cable to get the clutch lever out of the clutch perch. If not then undo the lock nut on the clutch cable adjusting barrel and screw that barrel in to get some more slack.
5 - Turn the clutch lever over, align the clutch cable with the slot and slide out the ferrule that holds the end of the clutch cable.
6 - Using a small socket or whatever, pound the old nylon sleeve out of the clutch lever.
7 - Insert the new sleeve into the bottom side of the clutch lever and pound it in until it is flush with the bottom face of the clutch lever.
8 - Put everything back together. Be sure to lube the cylindrical ferrule and the pivot pin with grease prior to reassembly. (The wave washer goes on the top of the nylon sleeve.)
9 - Don't forget to reattach the other end of the clutch cable and readjust the barrel as necessary. It's probably not a bad idea to make sure that your clutch is properly adjusted while you're at it. Here:
K bike clutchesReplacing the brake lever sleeve on a 4V K:(see attached diagram below)
4V brake lever nylon sleeve (bush) part #: 32722310754
(Note that the parts diagram shows the pivot pin coming in from the top. It actually comes in from the bottom.)
1 - Remove the Phillips head machine screw(17) from lower front of the throttle perch assembly and remove the odd-shaped plastic cap(16.) See that screw with red paint on it? There's no need to mess with that.
2 - Use a 5mm Allen wrench to unscrew the pivot pin from below. Once it gets to the end of it's threads it can be a bugger to get the rest of the way out. Try applying angular force to the Allen wrench while pulling down on it to work it the rest of the way out. Once enough of it's head is exposed use some pliers or, God forbid, some Vise-Grips, to get it the rest of the way out. Then remove the brake lever.
3 - Pound the old sleeve out and the new one it.
4 - When putting the brake lever back on be sure that it contacts the brake switch correctly. Also be sure that the ball-jointed rod that pushes on the master cylinder piston goes into the master cylinder piston.
5 - Put some grease on the portion of the pivot pin where the sleeve rotates, some blue(medium) Loctite on the threads and screw it in.
6 - Make sure rubber boot is properly seated on the master cylinder.
7 - Reinstall the black plastic cover.
To lube a 2V pivot pin all you need to do to remove that pin is use a regular screwdriver on the top of it and an open-ended 10mm box wrench on the bottom to pull it out from the top.
