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Help Zeal - replacing brake and clutch levers

Discussion in 'Yamaha 250cc In-Line 4's' started by fzxcraignz, Jun 1, 2019.

  1. fzxcraignz

    fzxcraignz Active Member

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    Hi all,

    Trying to install after market levers on my 92 Zeal, hit a snag when trying to replace the broken brake lever. Can't remove the swivel piece in the middle to use with new lever. Is this even possible or do I need to find a new one somewhere?

    IMG_4721.JPG IMG_4722.JPG IMG_4723.JPG IMG_4724.JPG
     
    fzxcraignz, Jun 1, 2019
    #1
  2. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    You need to remove the circlip. It is visible on the first picture. Use two small flat blade screwdrivers and apply even pressure wherever you can get them in. Don't lose it! It'll want to ping away on you. And don't stab yourself with the screwdrivers :)
     
    Linkin, Jun 1, 2019
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  3. fzxcraignz

    fzxcraignz Active Member

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    cheers for that, have been trying! will give it another go :)
     
    fzxcraignz, Jun 1, 2019
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  4. jmw76

    jmw76 Well-Known Member

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    Try tapping a flat piece of steel (same thickness as circlip) into the groove where the open ends of the circlip are.
    This may be enough to push the circlip out a bit so you can get a small screwdriver under it and flick it off.
     
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    jmw76, Jun 1, 2019
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  5. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    I'm guessing that circlip look's like this one

    [​IMG]

    Just get a small flat head screwdriver and push it in where the arrow is marked, then give it a twist either way and try levering it out
    If you put a finger from your other hand near the back of the circlip or even a cupped hand over it you may be able to catch it as it comes out
    Do it somewhere there isn't a heap of stuff on the ground, or with a lot of hiding places

    fzx brake lever.JPG
     
    • Agree Agree x 1
    my67xr, Jun 2, 2019
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