Installing Old Honda Style Levers: From Cable Removal to Clutch Adjustment

01 Before the job

Old Honda Style Levers are for drum-brake bikes only. So we start removing the brake cable from the drum side.

02 Removing the cables and levers

1. Use a 12mm wrench to loosen the double nuts that hold the cable to the brake panel. Fully loosen the nut on the right as you face it and slide it down to the position shown. Lightly holding the brake rod by hand makes the nut easier to loosen.
   
2. Once the nut on the panel side is loose, the cable at the lever end gets slack and comes off easily.
   
3. Remove the throttle, switches and anything else in the way, then slide off the lever. This is a good time to clean off any grime stuck to the handlebar.
   
4. The clutch cable comes off just by adjusting the adjuster at the lever.
   

03 Installing the clutch lever

Slide the clutch lever onto the cleaned handlebar.

It went on easily this time, but depending on the thickness of the bar's paint or plating, it can be tight. When fitting universal levers, the sure way is to take the time to remove the clamp bolt first.

If it's still tight, insert a flat-head screwdriver into the slit in the clamp and spread it slightly as you slide it on.

The lever position depends on things like the size of the switches you'll fit, so set it by test-fitting. As a guide, lining up the tip of the lever with the face of the bar end usually works well.

Once you've found roughly the right spot, snug the clamp bolt lightly. We'll do the final positioning all at once later.

04 A clutch adjustment worth doing while you're at it

With the cable off for the lever swap, it's the perfect time to adjust the clutch as well. When this part wears, the clutch starts to feel off.

1. Above and to the left of the front sprocket is a 17mm nut with a cross slot in its center. Put a 17mm box-end wrench on it and loosen it.
   
2. Once it's a little loose, the nut turns by hand. Leave it slightly loose and insert a Phillips screwdriver into the cross slot in the center.
   
3. As you turn the screwdriver, you'll see the push lever move with it.
   
4. With the screwdriver in place, turn it in until it gets firm. Then back it out little by little until the mark on the crankcase lines up with the center of the push lever pin.
   
5. Once it's in position, tighten the 17mm nut to lock it. Then just attach the clutch cable to the lever and you're done.
   

05 Installing the brake lever

Next is the brake lever. If you're using the optional Brake switch for old Honda-style levers, install it at this stage.

1. Fold the lever and insert the brake switch from the outside in.
   
2. Line up the tab, insert it and mount it on the bar, and it looks like this.
   
3. Loosely attach the brake cable to the lever, then roughly set the brake position at the brake panel.
   
4. Push the arm to reduce the brake free play and lock it with the nut.
   
5. Tighten the nut firmly while checking that the brake isn't dragging and, on the other hand, that there isn't too much free play.
   

06 Final adjustment and wiring

With both levers on, sit on the bike. Fine-tune them while checking that the left and right levers match in position and angle.

Make sure you haven't forgotten to tighten not only the handlebar clamps but also the bolts and nuts at the lever pivots.

Finally, connect the brake switch to the harness and you're done. On the SR, connect yellow/green to yellow/green and black to light brown.

Just changing the levers makes the cockpit look much cleaner. Once you know the steps, it's a job you can easily handle yourself.