How do you guys clear your Pazzo levers?

gagan_singh

gagan_singh

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hey guys,
ok so when i bought my 2010 ninja 650r the previous owner had the clutch side pazzo lever installed. the brake side had a issue as it was rubbing something on the sport bars. so i decided to install it today and see what the issue is. basically the push rod pin that goes into to the mc was to long so i made a custom one and made it fit. after putting everything together with the new pazzo's i noticed on full lock of the sport bars the brake lever was hitting the fairing/ windscreen. this was preventing me from turning full to the left, and when i did the front brake would engage .

so my question is, is this normal for the aftermarket levers to not clear with sport bars? this is my first bike so im not to sure how everything is supposed to be exactly.

ps. i did try searching on this forum and google but there wasn't any definitive answers.

THANKS in advance!!
 
I don't have pazzos but similar styled levers that would hit the front fairing as well. I played around with the lever settings and also adjusted the angle of it up and down until I found an acceptable compromise. Levers were still comfortable to reach/pull and only made feather light contact with the plastics.
 
AF4iK said:
I don't have pazzos but similar styled levers that would hit the front fairing as well. I played around with the lever settings and also adjusted the angle of it up and down until I found an acceptable compromise. Levers were still comfortable to reach/pull and only made feather light contact with the plastics.
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ok thanks, i was thinking of adjusting them but just wanted to find out if this was normal though.

one more question, when u installed them did u use the original pin that that going to the master? for me it was no where close to ever fitting so i took a bit from a screwdriver set and made a custom one.
 
Try looking at the dimple in the lever. There's a stopper in there that u can rotate to have a small well for the rod to sit in.

I have an imitation, might be similar.

Sent from my tablet using my paws
 
RockerGuy said:
Try looking at the dimple in the lever. There's a stopper in there that u can rotate to have a small well for the rod to sit in.

I have an imitation, might be similar.

Sent from my tablet using my paws
Click to expand...

i just went and looked at the lever. its just a round smooth end with a egde on the end. nothing there to have the rod sit in. i did grind a egde into the lever, thats what allowed me to use the screwdriver bit.

the pic is not of mine but they are the exact same. the top one is the brake side, as u can see there isnt really anything for the rod to sit into like the stock one has.
1200717260216-920673215.jpeg
 
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gagan_singh said:
i just went and looked at the lever. its just a round smooth end with a egde on the end. nothing there to have the rod sit in. i did grind a egde into the lever, thats what allowed me to use the screwdriver bit.

the pic is not of mine but they are the exact same. the top one is the brake side, as u can see there isnt really anything for the rod to sit into like the stock one has.
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Hmm is it possible you got the wrong levers? I happen to have a spare set with me here that the prev owner of my bike gave to me because he had bought the wrong ones. They look nearly identical to yours. Of course, you and I have different bikes though.

[edit] I found this PDF online (see pic 2) at the following page: http://www.motoworldonline.com/Pazz...inja-650R-Versys-ER-6N-2009-2010_p_3073.html# [/edit]
 
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You might have better luck asking on a site like KawiForums.com, RiderForums.com, brp650forum.com, (all those 3 are either Ninja 650R specific or have specific sections for the 650R) or maybe the tech section of this site...
 
I have the exact same levers (Pazzo Shorty) and Sport Bars. What the Dealer did was install the Sport Bars so the bars are approx 1'' past the hole opening. In other words the Bars (both sides - clutch and brake side) is not flush with the end of the clamp sleeve it goes into. Then they adjusted the angle (rotate) of the bars so that the levers-and brake master cylinder are slightly tilted up. My levers do still touch the windscreen on full lock and the brake lever still gets slightly pushed in. But the brake does not engage yet. The way I see it you would very rarely ride the bike in the full lock position. I can easily access the the brake lever in full lock.

I think the problem we have is that the Pazzo levers have the perch sticking out further than the stock levers. Otherwise the Sport Bars and stock levers don't touch the screen.
 
AF4iK said:
Hmm is it possible you got the wrong levers? I happen to have a spare set with me here that the prev owner of my bike gave to me because he had bought the wrong ones. They look nearly identical to yours. Of course, you and I have different bikes though.

[edit] I found this PDF online (see pic 2) at the following page: http://www.motoworldonline.com/Pazz...inja-650R-Versys-ER-6N-2009-2010_p_3073.html# [/edit]
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the owner before me had these installed at kahuna and i think after having no idea what the issue is. i think once the weather gets better ill just take it there and ask them. i cant help but think that im missing a part, im 90% sure the m/c bracket is missing (the one in pic 2). so heres a crap load of pics of the actual one that might help...

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Are they real Pazzo's of china knock offs? Cause for a $100 lever I would assume they would have designed them with a notch in it for the rod.
 
That lever looks like it has piece broken off at the end where it pushes the brake master cyclinder piston? That's probably why they put the stock lever back on.
 
250R-ICE said:
That lever looks like it has piece broken off at the end where it pushes the brake master cyclinder piston? That's probably why they put the stock lever back on.
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OP, if it turns out that it's the broken piece causing the problem you're welcome to take the bracket part off my lever. I don't know if it's exactly the same but it looks like it...

brakelever.jpg
 
AF4iK said:
OP, if it turns out that it's the broken piece causing the problem you're welcome to take the bracket part off my lever. I don't know if it's exactly the same but it looks like it...

brakelever.jpg
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theres nothing broken off, after trying to get that full brand new bracket to fit for an hour, i decided to custom make my own one cause the original was a lost hope. i made my own notch in it so the screwdriver bit i was using wouldn't slide out.

i think when i get some time im going to install the pazzo lever as i did before with the screwdriver bit and just adjust it for clearance issues. if the clearance is decent then ill just keep that in...

THANKS so much everybody for the help really appreciate it!!!
 
Xtina said:
Are they real Pazzo's of china knock offs? Cause for a $100 lever I would assume they would have designed them with a notch in it for the rod.
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as far as i know they are real, the previous owner did not cheap out on anything!! but i cant be for sure as replicas these days really do look real.
 
gagan_singh said:
the owner before me had these installed at kahuna and i think after having no idea what the issue is. i think once the weather gets better ill just take it there and ask them. i cant help but think that im missing a part, im 90% sure the m/c bracket is missing (the one in pic 2). so heres a crap load of pics of the actual one that might help...


20130225_130237.jpg
Click to expand...

That lever does not look like it will positively hold the end of the master cylinder plunger, I'd throw that thing in the bin man. Of all the 100's of parts on your bike, this is not the part to be fooling with. Get one that fits right.
 
mikbusa said:
Of all the 100's of parts on your bike, this is not the part to be fooling with. Get one that fits right.
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I agree with this unless you know what you're doing. Anyway my offer still stands if you decide you want a fresh part.
 
AF4iK said:
I agree with this unless you know what you're doing. Anyway my offer still stands if you decide you want a fresh part.
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ye idk what to do with it. im in the hwy 7 and 50 area in brampton. if your not to far away i might just drop by and pick it up :) just pm me i guess THANKS
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