Installing a rear brake lever correctly is crucial for your dirt bike's safety and performance. This step-by-step guide will walk you through the proper replacement process, ensuring your brake lever functions perfectly. Make sure to watch the video for a visual walkthrough.

Required Tools to get the job done:

• Long nose pliers

• Socket set and ratchet spanner

• Thread lock

• New split pin

• Clean cloth for cleaning parts

Step-by-Step Process:

Spring Removal

First, remove the return spring using long nose pliers. Carefully detach it from both the lever and engine casing points. Set this spring aside as it will be reused later.

Pump Linkage Disassembly

Remove the clip piece that connects to the master cylinder. Note that the split pin on the back typically needs replacement as they tend to snap during removal. Carefully separate this connection from the brake lever assembly.

Main Bolt Removal

• Hold the nut on the back with a ratchet spanner

• Remove the main allen bolt

• Push the bolt through with your finger

• Slide the old brake lever out

Pro Tip: When examining your old brake lever, check the bearing inside. Wear in this bearing often causes excessive play in the lever. While you can replace just the bearing, many riders opt for a complete lever assembly when damage occurs.

Installation of New Lever

• Position the new lever in place

• Clean the original bolt thoroughly if reusing it

• Apply a thin layer of thread lock to the bolt

• Insert the bolt through the lever and frame

• Attach and tighten the nut securely

Reassembly

• Reinstall the pump linkage clip

• Insert a new split pin and fold it properly

• Reattach the return spring, starting with the bottom connection

• Complete the installation by securing the top spring connection

Pro Tip: The brake tip (end piece) is customizable. You can purchase extended or stronger replacement tips, particularly useful for bikes with engine covers where boot access might be limited.

Final words

When done correctly, this entire process should take between 5-10 minutes. Proper installation ensures safe and reliable brake operation, which is crucial for your riding safety.

Author information

My name is Charlie Frost, and I'm no stranger to the adrenaline-fueled world of extreme enduros. Starting my journey at 19, I seamlessly blended trials and enduro racing, honing my skills through youth events and extreme races like the Tough One and Erzberg. When I'm not tearing through rugged terrain, you can often find me in front of the 24MX camera, sharing my passion and insights with fellow riders, as we delve into the exhilarating world of off-road racing.