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<onlyinclude>
This replaces the [[Front Brake Lever|Brake Lever]].
;Manual for a MY2016 DSR, applies to 2014+ models with JJuan front brake systems.
: [[File:FBLMY2016REPAIR02.jpg|thumb|none|Broken brake lever from 2016 DSR]] [[File:FBLMY2016REPAIR01.jpg|thumb|none|JJUAN FRONT BRAKE LEVER SDS 25-0803201]]
; Parts
* JJUAN FRONT BRAKE LEVER SDS 25-0803201 $76 USD
* JJUAN FRONT BRAKE LEVER SDS 25-08032 (alternate) $76 USD
;Tools
: [[File:FBLMY2016REPAIR03.jpg|thumb|none|5mm Allen key and 10mm socket]]
* 5mm Allen key (above)
* 10mm hex socket (below)
;Removal
# Remove bottom 10mm lock nut. [[File:FBLMY2016REPAIR04.jpg|thumb|none]]
# Loosen top 5mm hex bolt. [[File:FBLMY2016REPAIR05.jpg|thumb|none]]
# Remove top 5mm hex bolt. [[File:FBLMY2016REPAIR06.jpg|thumb|none]]
# Slide out brake lever assembly. [[File:FBLMY2016REPAIR07.jpg|thumb|none]]
# Inspect brake lever mount for damage [[File:FBLMY2016REPAIR08.jpg|thumb|none]]
;Replacement
# Remove bottom 10mm lock nut from 5mm hex bolt and set both pieces aside.
#: [[File:FBLMY2016REPAIR09.jpg|thumb|none]] [[File:FBLMY2016REPAIR10.jpg|thumb|none]]
# Slide in brake lever assembly, taking care to align the rubber boot / plunger (''what's the technical term?'') and the bolt hole.
#: [[File:FBLMY2016REPAIR11.jpg|thumb|none]] [[File:FBLMY2016REPAIR12.jpg|thumb|none]]
# Insert 5mm hex bolt from top to bottom and hand-tighten with 5mm hex bit on top until snug.
#* Do not over-torque.
#* Hold the 5mm hex bit in place for the next step.
# Fasten threads with 10mm lock nut and hand-tighten until snug.
#* Do not over-torque.
# [[Front Brake Lever Adjustment|Adjust a set screw on the inside of the lever]], if necessary.
;Left-over parts
* The old brake lever assembly.
;Manual for a MY2012 XU.
: [[[[File:parts.jpg|400px]]|thumb|none|New lever, bolt and nut and the small spring ]]
; Parts
* 2012 XU FRONT BRAKE LEVER (I found one on ebay)
;Tools
* 10mm hex socket
;Removal
# Remove bottom 10mm lock nut.
# Loosen top 10mm hex bolt.
# Remove the broken lever, paying attention no to lose a small steel spring between the lever and the handle (see picture above).
;Replacement
# Slide in brake lever assembly, taking care to align the rubber boot / plunger and the bolt hole.
# Insert 10mm hex bolt from top to bottom and hand-tighten with 10mm hex bit on top until snug.
#* Do not over-torque. Test.
;Left-over parts
* The old brake lever assembly.
; Newer brake lever model
: [[File:Brake lever tagged.jpg|thumb|none]]
: Newer replacement parts seem to contain an extra screw (G) used to fit the length of the piston (E) into the cylinder.
: With this replacement part, assemble by:
# Put part D into the lower hole of the lever (A).
# Screw the piston (E) into the visible hole of part D.
# Put the rubber boot (F) onto the piston (E), so that it looks like in the assembled version shown before.
# Screw the small screw (G) from the side into part D to fix the piston (E).
#: Keep it loose, though, so that you can still screw out or in the piston (E).
# Slide the lever into the bracket as shown before.
#: Insert the hex bolt, but do not tighten it.
# Check the function of the brake, especially any slack it shows.
# In case you have slack, take out the hex bolt, slide the lever out again and adjust the length of the piston by slightly screwing it out.
# Reassemble into the bracket and recheck the function of the brake.
#: If you are happy with it, then tighten the small screw (G) to fix the length of the piston.
</onlyinclude>
[[Category:Procedure]]
[[Category:Teardown]]
[[Category:Repair]]
This replaces the [[Front Brake Lever|Brake Lever]].
;Manual for a MY2016 DSR, applies to 2014+ models with JJuan front brake systems.
: [[File:FBLMY2016REPAIR02.jpg|thumb|none|Broken brake lever from 2016 DSR]] [[File:FBLMY2016REPAIR01.jpg|thumb|none|JJUAN FRONT BRAKE LEVER SDS 25-0803201]]
; Parts
* JJUAN FRONT BRAKE LEVER SDS 25-0803201 $76 USD
* JJUAN FRONT BRAKE LEVER SDS 25-08032 (alternate) $76 USD
;Tools
: [[File:FBLMY2016REPAIR03.jpg|thumb|none|5mm Allen key and 10mm socket]]
* 5mm Allen key (above)
* 10mm hex socket (below)
;Removal
# Remove bottom 10mm lock nut. [[File:FBLMY2016REPAIR04.jpg|thumb|none]]
# Loosen top 5mm hex bolt. [[File:FBLMY2016REPAIR05.jpg|thumb|none]]
# Remove top 5mm hex bolt. [[File:FBLMY2016REPAIR06.jpg|thumb|none]]
# Slide out brake lever assembly. [[File:FBLMY2016REPAIR07.jpg|thumb|none]]
# Inspect brake lever mount for damage [[File:FBLMY2016REPAIR08.jpg|thumb|none]]
;Replacement
# Remove bottom 10mm lock nut from 5mm hex bolt and set both pieces aside.
#: [[File:FBLMY2016REPAIR09.jpg|thumb|none]] [[File:FBLMY2016REPAIR10.jpg|thumb|none]]
# Slide in brake lever assembly, taking care to align the rubber boot / plunger (''what's the technical term?'') and the bolt hole.
#: [[File:FBLMY2016REPAIR11.jpg|thumb|none]] [[File:FBLMY2016REPAIR12.jpg|thumb|none]]
# Insert 5mm hex bolt from top to bottom and hand-tighten with 5mm hex bit on top until snug.
#* Do not over-torque.
#* Hold the 5mm hex bit in place for the next step.
# Fasten threads with 10mm lock nut and hand-tighten until snug.
#* Do not over-torque.
# [[Front Brake Lever Adjustment|Adjust a set screw on the inside of the lever]], if necessary.
;Left-over parts
* The old brake lever assembly.
;Manual for a MY2012 XU.
: [[[[File:parts.jpg|400px]]|thumb|none|New lever, bolt and nut and the small spring ]]
; Parts
* 2012 XU FRONT BRAKE LEVER (I found one on ebay)
;Tools
* 10mm hex socket
;Removal
# Remove bottom 10mm lock nut.
# Loosen top 10mm hex bolt.
# Remove the broken lever, paying attention no to lose a small steel spring between the lever and the handle (see picture above).
;Replacement
# Slide in brake lever assembly, taking care to align the rubber boot / plunger and the bolt hole.
# Insert 10mm hex bolt from top to bottom and hand-tighten with 10mm hex bit on top until snug.
#* Do not over-torque. Test.
;Left-over parts
* The old brake lever assembly.
; Newer brake lever model
: [[File:Brake lever tagged.jpg|thumb|none]]
: Newer replacement parts seem to contain an extra screw (G) used to fit the length of the piston (E) into the cylinder.
: With this replacement part, assemble by:
# Put part D into the lower hole of the lever (A).
# Screw the piston (E) into the visible hole of part D.
# Put the rubber boot (F) onto the piston (E), so that it looks like in the assembled version shown before.
# Screw the small screw (G) from the side into part D to fix the piston (E).
#: Keep it loose, though, so that you can still screw out or in the piston (E).
# Slide the lever into the bracket as shown before.
#: Insert the hex bolt, but do not tighten it.
# Check the function of the brake, especially any slack it shows.
# In case you have slack, take out the hex bolt, slide the lever out again and adjust the length of the piston by slightly screwing it out.
# Reassemble into the bracket and recheck the function of the brake.
#: If you are happy with it, then tighten the small screw (G) to fix the length of the piston.
</onlyinclude>
[[Category:Procedure]]
[[Category:Teardown]]
[[Category:Repair]]