DL1000 Clutch Lever Removal:

Tools Required:
  • 12mm wrench
  • 10mm wrench
  • Phillips head screwdriver
  • Grease

This is a very simple procedure. Start by removing the knuckle guard. This is held in place by 1 phillips head screw and two tension clips molded into the guard.

Once you have removed the knuckle guard you will see this tall bolt. This is what holds the lever in place. Underneath you will see two (2) 10mm nuts. Remove these first (obviously) and then remove the bolt using a 12mm wrench.

At this point the lever is ready to be removed. Pay attention because there are a couple of parts that will get away from you if you’re sloppy. There is a brass swivel that just sits in its hole and if you are not watching it will fall right out when you remove the lever (the one pictured is held in place by grease). The same goes for the piston that fits into the master cylinder.

One thing you should do before reinstalling your lever is to grease this brass swivel. After about 20,000 miles mine was almost destroyed from moving without lubricant. The soft brass just slowly grinds down to nothing.

*NOTE* the procedure for removing the Brake lever on a DL1000 is the same as the clutch lever, with the one exception of the brake lever being on the other side.
Reassembly is the reverse of the above procedure. This removal/replacement should take all of about 10 minutes to complete.