Front Brake Lever Replacement

This replaces the Brake Lever.

Manual for a MY2016 DSR, applies to 2014+ models with JJuan front brake systems.

Broken brake lever from 2016 DSR

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

5mm Allen key and 10mm socket

• 5mm Allen key (above)
• 10mm hex socket (below)

Removal

1. Remove bottom 10mm lock nut.
   
2. Loosen top 5mm hex bolt.
   
3. Remove top 5mm hex bolt.
   
4. Slide out brake lever assembly.
   
5. Inspect brake lever mount for damage
   

Replacement

1. Remove bottom 10mm lock nut from 5mm hex bolt and set both pieces aside.

   

   

2. Slide in brake lever assembly, taking care to align the rubber boot / plunger (what's the technical term?) and the bolt hole.

   

   

3. 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.
4. Fasten threads with 10mm lock nut and hand-tighten until snug.
   • Do not over-torque.
5. 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.

[[|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

1. Remove bottom 10mm lock nut.
2. Loosen top 10mm hex bolt.
3. Remove the broken lever, paying attention no to lose a small steel spring between the lever and the handle (see picture above).

Replacement

1. Slide in brake lever assembly, taking care to align the rubber boot / plunger and the bolt hole.
2. 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

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:

1. Put part D into the lower hole of the lever (A).
2. Screw the piston (E) into the visible hole of part D.
3. Put the rubber boot (F) onto the piston (E), so that it looks like in the assembled version shown before.
4. 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).

5. Slide the lever into the bracket as shown before.

   Insert the hex bolt, but do not tighten it.

6. Check the function of the brake, especially any slack it shows.
7. 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.
8. 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.