Lever Question

oldjapanesebikes · Post by **oldjapanesebikes** » Sat Dec 17, 2011 11:15 pm

So I've got the lights working again, brake light works, horn works, I've added a centre stand, have put together most of an original tool kit and have started to do some tuneup/servicing on the 1968 CL77 I recently bought. I'm just curious about one thing. The clutch and brake levers do not match. Are they supposed to ? Here is a photo of the clutch lever which I am sure is original:

The brake lever has a round ball. is that correct ? I don't ever recall seeing a flat end brake lever, but than again I could be wrong. Comments appreciated !

Snakeoil · Post by **Snakeoil** » Sun Dec 18, 2011 10:22 am

My understanding is the flat end levers are intended to have black rubber tip covers over that end. The rubber covers are round.

That is what should be on my bike and I actually bought a NOS pair of covers from somebody here (short memory). I tried every possible way to install them and ended up tearing one, so I just threw the other on the bench and quit. Not something I do regularly.

Anyone have a method to install those covers? Honda either had a special tool or the covers were molded over the levers at the factory.

regards,
Rob

Dgormley · Post by **Dgormley** » Sun Dec 18, 2011 7:11 pm

When I got my 66 CL the levers were flat on the end and covered in a very thick layer of clear (yellowed) plastic about 3/4 the way up the lever. I,m thinkin a long hot soak in soapy water might get those rubber thingies on....................D

Buck · Post by **Buck** » Sun Dec 18, 2011 7:30 pm

I've tried putting those on also. Tried boiling them,lube on them,heat gun etc..No way they would go on. I was told to turn them inside/out and install. Have not done this as mine were torn from trying everything else. If this works I will order more for my 67 CL. Buck

FAST FRED · Post by **FAST FRED** » Sun Dec 18, 2011 8:21 pm

I have heard all the tricks too but have not talked to anybody that has had much luck with these. I have a good friend Vic whose been a Honda mechanic for 40 years, when I asked him about installing them back in the day, He tells me they had no real problems slipping them on with out tearing. His favorite method was to soak the rubber in water and slipping it over the ball while appling air preasure to the backside thru the small hole. Sounds crazy but Vic is the man on issues like this around here. I think the rubbers when new 45 years ago were fresh rubber and way more plyable than they are today. Thank God my resto is a 65 and I don't need a set.

Fast Fred

Hoosier Tom · Post by **Hoosier Tom** » Sun Dec 18, 2011 9:57 pm

I used liquid dish washing soap, Dawn I think, not that the brand really matters. Warmed the rubber out in the sun then lubed the inside of the rubber with dish soap then the end of the lever. It's been a few years since I did it but didn't have a problem getting them on.

Good luck- HT

Snakeoil · Post by **Snakeoil** » Mon Dec 19, 2011 11:52 am

No hole in the ones I had. I tried shooting air into the opening while fitting them. But with soap on them to help, they were hard to hold onto and all I did was launch them across the basement.

Inside out sounds like it might work. Of course turn them inside out will be a challenge in and of itself. I'll see if I can find that one I have and turn it inside out.

The feature that might make this hard is the inside has a thick section where the flat on the ball end of the lever is. It's a hemisphere of rubber.

Fast Fred, did I get mine from you?

regards,
Rob

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