DIY: Installing Pazzo Adjustable Levers - Page 2

noche_caliente · October 6th, 2009, 03:08 PM

Deb, for me it's because my hands are tiny and it was a long reach that was causing ligament strain that was painful - now I don't have any problems with it

darkknight49 · October 6th, 2009, 05:10 PM

man, i wish i had a garage right now. Then I'd be able to do a lot of the mods i want.

Nemesis · October 6th, 2009, 06:02 PM

Not sure if you mentioned this or not but how much did you pay for those? I'm in the market for some levers.

HKr1 · October 6th, 2009, 08:11 PM

Quote:

Originally Posted by darkknight49

man, i wish i had a garage right now. Then I'd be able to do a lot of the mods i want.

No garage needed for the pazzo install

Quote:

Originally Posted by Nemesis

Not sure if you mentioned this or not but how much did you pay for those? I'm in the market for some levers.

Motomummy probably has the best deal:
http://www.motomummy.com/store/home.php?cat=357

Bought all my levers(except one) from corey. Still makes me smile to see my yellow bike on that page....

Nemesis · October 6th, 2009, 08:26 PM

Am I reading this right? One size fits all?

noche_caliente · October 7th, 2009, 03:03 PM

Are you reading what right?

craha · November 22nd, 2009, 04:04 PM

Felt I should add a warning to this thread. I just installed my Pazzo shortys and broke the pin of the Starter Lockout Switch. It's located under a tab on the clutch lever base. It is very small and clearly more delicate than I thought. I wasn't being careful enough I guess... Anybody know how much this part goes for? Any thoughts?

HKr1 · November 22nd, 2009, 04:25 PM

Quote:

Originally Posted by craha

Anybody know how much this part goes for? Any thoughts?

Bummer!

They sell for 20 bucks.

craha · November 23rd, 2009, 09:23 PM

Thanks. Hopefully I'll get around to replacing that soon. I'm in no hurry though as it's not a critical part. Having too much fun playing with the setting on the new levers!

Mr_Pete · December 23rd, 2009, 09:44 PM

Just picked up a set of these for my fiancé for Christmas. I was up in the air about shorties vs. regulars and ended up going with the regulars. Hope she'll like them.

HKr1 · December 23rd, 2009, 09:56 PM

Quote:

Originally Posted by Mr_Pete

Just picked up a set of these for my fiancé for Christmas. I was up in the air about shorties vs. regulars and ended up going with the regulars. Hope she'll like them.

Nice stocking stuffer

Dino · September 11th, 2010, 05:14 PM

Quote:

Originally Posted by craha

Thanks. Hopefully I'll get around to replacing that soon. I'm in no hurry though as it's not a critical part. Having too much fun playing with the setting on the new levers!

It's a good thing you mentioned this because I wouldn't have remembered about this piece. Does anyone know what it's function is for and is it really necessary to drive the bike? I heard a snapping sound while installing the levers and could not for the life of me figure it out until I came upon this note. Sure enough when I checked under there, I saw that the little plastic rod that was sticking out was broken off.

snowsoldier · April 1st, 2011, 05:55 PM

hey, what kind of torque wrench did you use??? is it completely necessary? I do not own one, and dont want to drop 80 bucks on a brand new one considering i just paid for these levers

any info would be greatly appreciated. thanks,

kkim · April 1st, 2011, 06:11 PM

for this, I wouldn't think so. The pivot bot already threads into the clutch perch and the nut on the end acts as a lock nut to the pivot bolt once it's assembled. Add the fact that the nut is a locking type nut, already, I highly doubt the pivot pin will back out. What I do suggest is that after the pivot bolt is installed (just snug it down) install the lock nut and tighten the nut so it just snugs the clutch perch and then back that nut off just a smidgen (perhaps 1/16 of a turn).

the clutch lever should be nice and free feeling as it pivots once you're done. Don't forget to grease the pivot bolt w/ some grease when you assemble it, along w/ some grease on the end of the clutch cable so the cable barrel pivots freely in the clutch lever.

snowsoldier · April 1st, 2011, 06:14 PM

thank you very much,

Heading outside to put em' on! cant wait!

snowsoldier · April 1st, 2011, 06:54 PM

not sure how tight 52 inch-lbs is, so I just tightened it firm, will this do?

(for the brake lever)

kkim · April 1st, 2011, 07:11 PM

52in/lbs~ 4ft/lbs.... like I said, just snug. The caution is that you don't want to over tighten it and deform the clutch perch by squeezing it together. deforming it could cause the lever to bind in the perch.

snowsoldier · April 1st, 2011, 09:16 PM

Then you should loosen the knurled locknut (larger clutch nut) by turning it towards the rear cowling. You want to screw in the adjuster towards the lever to give it as much play as possible. Once it is all the way in, align the slots in the knurled locknut and the adjuster nut with the slot in the backside of the lever. I found that it was easier to lift the lever off and flip it over, then do this.

having troubles, i have removed the 8mm bolt and loosened the knurled clutch nut

kkim · April 1st, 2011, 09:32 PM

Quote:

Originally Posted by snowsoldier

having troubles, i have removed the 8mm bolt and loosened the knurled clutch nut

... and??

have you seen this DIY? pics might help you with your problem.
http://www.ninjette.org/forums/showthread.php?t=10016

snowsoldier · April 1st, 2011, 10:29 PM

all done, they look sweet. i love em

Koz2010 · April 5th, 2011, 03:18 PM

I'm wondering if anyone can help...I installed the brake lever without any problem. Then when I went to do the clutch side I ran into a problem. The 8mm nut underneath spins the whole bolt when turned. I've tried holding the bolt in place with vice grips so it doesn't spin and then tried to undo the nut... and nothing. The nut just spins in place... any ideas on how to get it off?

kkim · April 5th, 2011, 03:24 PM

sounds like someone stripped the threads on the bolt by over tightening the nut. used bike?

to get the nut off, try applying some pressure to the nut while backing it off by wedging a flat blade screwdriver between the nut and the clutch perch.

Koz2010 · April 5th, 2011, 03:29 PM

Quote:

Originally Posted by kkim

sounds like someone stripped the threads on the bolt by over tightening the nut. used bike?

to get the nut off, try applying some pressure to the nut while backing it off by wedging a flat blade screwdriver between the nut and the clutch perch.

Yea, it's a used bike. I don't know why someone would've took the lever off before though as it doesn't look like it's been dropped. I'll try the screwdriver idea but first I'm going to have to go buy a new bolt and nut so that I can put it back together after. Thanks

kkim · April 5th, 2011, 03:37 PM

just be aware that's not a normal bolt, but has a long section of it that's non threaded so the lever can pivot on it. only place to get one would be the dealer or online OEM parts supplier. You should be able to reuse the original nut if you can get it off easily with the screwdriver trick.

If I had to guess, they tried tightening up the clutch lever nut to stop the clutch lever rattle that's inherent on these bikes and over tightened it to the point of stripping the threads on the bolt.

try taking it off and see what's up. You may be able to reuse both the nut and bolt.

jamesio · July 7th, 2011, 12:34 PM

Just installed my pazzos yesterday...they look and feel great. I'll put some pics up soon.

I have them set all the way to 6...I have large hands and long fingers so any lower and when I go to grab the lever my fingers will kind of hit the lever. At the 6 setting I can go from the handle to the grip very smoothly and don't have to worry about getting my fingers out from underneath the lever.

October 6th, 2009, 03:08 PM	#41
noche_caliente ninjette.org certified postwhore Name: Kim Location: mundo de ensueño Join Date: Nov 2008 Motorcycle(s): '08 250 Posts: A lot.	Deb, for me it's because my hands are tiny and it was a long reach that was causing ligament strain that was painful - now I don't have any problems with it __________________________________________________ Progrip tank pad, blue rim stripes, blue Pazzos, Roaring Toyz lowering kit, Puig DB in dark smoke, Cortech sport tail, super mini tank, and saddlebags, OES swingarm spools and Intuitive frame sliders

October 6th, 2009, 05:10 PM	#42
darkknight49 ninjette.org member Name: Faiyaz Location: Davis, Ca Join Date: Jan 2009 Motorcycle(s): Black 08 Ninja 250 Posts: 70	man, i wish i had a garage right now. Then I'd be able to do a lot of the mods i want. __________________________________________________ 2008 Ninja 250 - Yoshi Exhaust, Brake Light Modulator, HID Kit To Come: Sliders, Fender Elim, Flush Mounts, Hugger (much later...no $ )

October 7th, 2009, 03:03 PM	#46
noche_caliente ninjette.org certified postwhore Name: Kim Location: mundo de ensueño Join Date: Nov 2008 Motorcycle(s): '08 250 Posts: A lot.	Are you reading what right? __________________________________________________ Progrip tank pad, blue rim stripes, blue Pazzos, Roaring Toyz lowering kit, Puig DB in dark smoke, Cortech sport tail, super mini tank, and saddlebags, OES swingarm spools and Intuitive frame sliders

July 7th, 2011, 12:34 PM	#65
jamesio ninjette.org guru Name: Moe Location: Earth Join Date: Jun 2011 Motorcycle(s): None Posts: 424	Just installed my pazzos yesterday...they look and feel great. I'll put some pics up soon. I have them set all the way to 6...I have large hands and long fingers so any lower and when I go to grab the lever my fingers will kind of hit the lever. At the 6 setting I can go from the handle to the grip very smoothly and don't have to worry about getting my fingers out from underneath the lever. __________________________________________________ '09 Ninja 250R SE TB Slip-On l Puig DB l Pazzos l Pro-Grips

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October 6th, 2009, 06:02 PM	#43
Nemesis CVMA #74 WSMC #750 Name: Nemesis Location: On the track Join Date: Oct 2009 Motorcycle(s): All of them Posts: A lot.	Not sure if you mentioned this or not but how much did you pay for those? I'm in the market for some levers.

October 6th, 2009, 08:26 PM	#45
Nemesis CVMA #74 WSMC #750 Name: Nemesis Location: On the track Join Date: Oct 2009 Motorcycle(s): All of them Posts: A lot.	Am I reading this right? One size fits all?

November 22nd, 2009, 04:04 PM	#47
craha ninjetter Name: Craig Location: Los Angeles Join Date: Mar 2009 Motorcycle(s): 2009 Ninja 250r Posts: 27	Felt I should add a warning to this thread. I just installed my Pazzo shortys and broke the pin of the Starter Lockout Switch. It's located under a tab on the clutch lever base. It is very small and clearly more delicate than I thought. I wasn't being careful enough I guess... Anybody know how much this part goes for? Any thoughts?

November 23rd, 2009, 09:23 PM	#49
craha ninjetter Name: Craig Location: Los Angeles Join Date: Mar 2009 Motorcycle(s): 2009 Ninja 250r Posts: 27	Thanks. Hopefully I'll get around to replacing that soon. I'm in no hurry though as it's not a critical part. Having too much fun playing with the setting on the new levers!

December 23rd, 2009, 09:44 PM	#50
Mr_Pete ninjette.org member Name: Pete Location: DMV Join Date: Oct 2009 Motorcycle(s): 2009 Ninja 250R Posts: 40	Just picked up a set of these for my fiancé for Christmas. I was up in the air about shorties vs. regulars and ended up going with the regulars. Hope she'll like them.

April 1st, 2011, 05:55 PM	#53
snowsoldier ninjette.org member Name: snowsoldier Location: Niagara Falls Join Date: Mar 2011 Motorcycle(s): 09 ninja 250r - yoshi slip-on, fender-elim, Pazzo levers, Pro-bolt gold mods, b-monkey ITL, SSR hanger/spools Posts: 69	hey, what kind of torque wrench did you use??? is it completely necessary? I do not own one, and dont want to drop 80 bucks on a brand new one considering i just paid for these levers any info would be greatly appreciated. thanks,

April 1st, 2011, 06:11 PM	#54
kkim Join Date: Nov 2008 Posts: Too much.	for this, I wouldn't think so. The pivot bot already threads into the clutch perch and the nut on the end acts as a lock nut to the pivot bolt once it's assembled. Add the fact that the nut is a locking type nut, already, I highly doubt the pivot pin will back out. What I do suggest is that after the pivot bolt is installed (just snug it down) install the lock nut and tighten the nut so it just snugs the clutch perch and then back that nut off just a smidgen (perhaps 1/16 of a turn). the clutch lever should be nice and free feeling as it pivots once you're done. Don't forget to grease the pivot bolt w/ some grease when you assemble it, along w/ some grease on the end of the clutch cable so the cable barrel pivots freely in the clutch lever.

April 1st, 2011, 06:14 PM	#55
snowsoldier ninjette.org member Name: snowsoldier Location: Niagara Falls Join Date: Mar 2011 Motorcycle(s): 09 ninja 250r - yoshi slip-on, fender-elim, Pazzo levers, Pro-bolt gold mods, b-monkey ITL, SSR hanger/spools Posts: 69	thank you very much, Heading outside to put em' on! cant wait!

April 1st, 2011, 06:54 PM	#56
snowsoldier ninjette.org member Name: snowsoldier Location: Niagara Falls Join Date: Mar 2011 Motorcycle(s): 09 ninja 250r - yoshi slip-on, fender-elim, Pazzo levers, Pro-bolt gold mods, b-monkey ITL, SSR hanger/spools Posts: 69	not sure how tight 52 inch-lbs is, so I just tightened it firm, will this do? (for the brake lever)

April 1st, 2011, 07:11 PM	#57
kkim Join Date: Nov 2008 Posts: Too much.	52in/lbs~ 4ft/lbs.... like I said, just snug. The caution is that you don't want to over tighten it and deform the clutch perch by squeezing it together. deforming it could cause the lever to bind in the perch.

April 1st, 2011, 09:16 PM	#58
snowsoldier ninjette.org member Name: snowsoldier Location: Niagara Falls Join Date: Mar 2011 Motorcycle(s): 09 ninja 250r - yoshi slip-on, fender-elim, Pazzo levers, Pro-bolt gold mods, b-monkey ITL, SSR hanger/spools Posts: 69	Then you should loosen the knurled locknut (larger clutch nut) by turning it towards the rear cowling. You want to screw in the adjuster towards the lever to give it as much play as possible. Once it is all the way in, align the slots in the knurled locknut and the adjuster nut with the slot in the backside of the lever. I found that it was easier to lift the lever off and flip it over, then do this. having troubles, i have removed the 8mm bolt and loosened the knurled clutch nut

April 1st, 2011, 10:29 PM	#60
snowsoldier ninjette.org member Name: snowsoldier Location: Niagara Falls Join Date: Mar 2011 Motorcycle(s): 09 ninja 250r - yoshi slip-on, fender-elim, Pazzo levers, Pro-bolt gold mods, b-monkey ITL, SSR hanger/spools Posts: 69	all done, they look sweet. i love em

April 5th, 2011, 03:18 PM	#61
Koz2010 ninjette.org newbie Name: Mario Location: Toronto Join Date: Jul 2010 Motorcycle(s): 2009 Kawasaki Ninja 250R Posts: 4	I'm wondering if anyone can help...I installed the brake lever without any problem. Then when I went to do the clutch side I ran into a problem. The 8mm nut underneath spins the whole bolt when turned. I've tried holding the bolt in place with vice grips so it doesn't spin and then tried to undo the nut... and nothing. The nut just spins in place... any ideas on how to get it off?

April 5th, 2011, 03:24 PM	#62
kkim Join Date: Nov 2008 Posts: Too much.	sounds like someone stripped the threads on the bolt by over tightening the nut. used bike? to get the nut off, try applying some pressure to the nut while backing it off by wedging a flat blade screwdriver between the nut and the clutch perch.

April 5th, 2011, 03:37 PM	#64
kkim Join Date: Nov 2008 Posts: Too much.	just be aware that's not a normal bolt, but has a long section of it that's non threaded so the lever can pivot on it. only place to get one would be the dealer or online OEM parts supplier. You should be able to reuse the original nut if you can get it off easily with the screwdriver trick. If I had to guess, they tried tightening up the clutch lever nut to stop the clutch lever rattle that's inherent on these bikes and over tightened it to the point of stripping the threads on the bolt. try taking it off and see what's up. You may be able to reuse both the nut and bolt.