Installing Chrome Levers: Adjusting Free Play and Using Cable End Covers
Simply replacing the stock levers with chrome levers changes the look of the handlebar dramatically. Using the SR as an example, we cover the installation steps, free play adjustment and how to remove and refit the cables.
- Things to know before fitting chrome levers
- How to set the lever free play correctly
- Why a cable end cover fills the gap in the cable end hole
- Removing, refitting and adjusting the brake and clutch cables
Even after tidying up the switches for a cleaner handlebar, the stock levers still leave a bulky look.
So this time we introduce chrome levers, an advanced item for handlebar customizing. Using an SR400 as an example, let's go through the actual installation steps and key points in order.
01 How chrome levers change the look
The simple shape and shine suit classic bikes, too. A single lever can completely change the feel of the handlebar.
Chrome levers cannot be fitted with a brake switch. Also, they do not have a decompression lever. Please keep these two points in mind when considering them.
02 Installing the lever itself
-
Remove the cables, switch box, grips and stock levers.
-
Clamp the chrome lever holder onto the handlebar. It looks finished at this point, but there's one more step.
-
Remove the lever pivot screw and apply grease to both the pivot and the lever.
- Set the lever in the holder and tighten the screw. The key here is to tighten it just enough that the lever doesn't have too much up-and-down play.
-
When the play is right, hold the top screw with a screwdriver and tighten the nut underneath.
03 Guide to lever play
Overtightening the screw makes the lever stiff. Find the point where there's no up-and-down wobble and it moves smoothly.
04 Attaching the cables and the cable end cover
All that's left is to attach the cables, but there's one thing to note here. Chrome levers weren't originally designed for Japanese bikes, so the hole that holds the cable end (the cylindrical metal fitting at the tip) is on the large side. Most cable ends on Japanese bikes are 8mm, while the hole in the chrome lever is 10mm. Fitted as is, there's a gap.
It still works this way, but for the sake of appearance we recommend fitting the optional cable end cover.
To install it, just slip the cable end cover over the cable end and fit it into the chrome lever.
Once the cables are on, adjust the brake and clutch and you're done.
05 Removing, refitting and adjusting the cables
To remove a cable, first loosen the nut at the brake panel.
Loosening it takes the tension off the lever, so the cable can be removed from the adjuster screw at the lever.
Refitting works the same way: tighten the brake panel side first. With most of the brake free play taken up, tighten the cable nut.
Fine-tune the brake with the adjuster screw at the lever. The more you turn the adjuster in the loosening direction, the sooner the brake engages.
After adjusting the brake, always spin the wheel and check that it isn't dragging. Likewise for the clutch: after adjusting, start the engine and make the final adjustment while checking the friction zone and so on.
06 Stainless screws to prevent rust
The screws used on the chrome levers are steel, so they inevitably rust when they get wet in the rain. If that bothers you, we recommend switching to the optional Stainless Slotted Screw Set. It gives a more unified look, too.
What we used
- Chrome Lever
- cable end cover
- Phillips screwdriver
- 10mm wrench (box-end wrench)
- Grease
Products featured in this article
More DIY articles
*Installation is at your own risk. If you're unsure about doing the work yourself, we recommend consulting your local motorcycle shop.
*The content and photos reflect the time of writing. Please check each product page for current specifications, fitment and stock.