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Brake Lever Rattle - How to Shim?

Bonaventure

Bonaventure

Cruisin' Guzzisti
Joined
Jul 30, 2017
Messages
181
Location
USA
My brake lever resonates at speed. The bars do not have any bad vibration and my hands remain comfortable yet the brake lever resonates on account of some slop in the fit. I removed and greased it thinking the grease might buffer it enough but no. It seems like an ultra thin washer of the correct dimensions would work to narrow up the hinge free space that's allowing the handle to resonate.

I actually thought it was valve clatter but it's the brake lever resonating. I want to correct it.

Clutch lever does not do this.
 
Go to a real hardware store and pick up some brass shim stock. I'd pick up 0.005 and 0.010m or use a feeler gauge to determine the space you need to take up than make a washer from that stock. Remember not to make the fit too tight as the lever must move freely or you brake master cylinder may not fully retract.
 
Thanks !! The feeler gauge idea is an excellent one, I have a gage with the flexible tab "deck of cards" feeler strips which should be ideal for that purpose. As for making/cutting the shim custom I might have a friend in a machine shop make it. I don't have the stuff to do it right and nice.
 
I had the same issue it was resolved by placing the pin on which it rotates.
 
Exactly remove both the lever and the pin determine which is worn in my case it was both so bad the holes on the lever were oval if they are that bad just get new ones
 
Not sure that's the cause in my case, the bike only has 4500 miles right now. Could still be, will have to check.
 
Two pics showing the wear on a pin and the wear on a lever.
This is what you have to look for in the event you have slop if no wear then it might be in the master itself.
Just a little more detail if this helps.
In my case the wear was over the course of 55K miles.

Pin1-L.jpg
lever3-L.jpg
 
DSM8 said:
Two pics showing the wear on a pin and the wear on a lever.
This is what you have to look for in the event you have slop if no wear then it might be in the master itself.
Just a little more detail if this helps.
In my case the wear was over the course of 55K miles.
Click to expand...

Thanks for the detailed reply. One thing I might try is swap pins with the clutch lever since they appear identical. The clutch lever does not resonate/vibrate. I will double check the hydraulic tension on the push plunger of the master.
 
Just pull the pin and look for wear it will be very evident if present same on the lever if it takes mote than 5 minutes to assess you are doing it wrong ;)
 
I got a pair of replacement levers for pretty cheap

Products
------------------------------------------------------
1 x Clutch lever for Griso, Norge, Breva 1100, Stelvio, Sport 1200 (AP8118659) = $39.09
1 x brake lever for CARC models: Griso Breva Norge Stelvio (981050) = $23.79
------------------------------------------------------
Sub-Total: $62.88

This was from MG Cycle dont know if this sites owner can get the same thing but at least above are some part numbers in case you need them.
 
If the bike didn't still smell new I'd be inclined to look into replacements but ... done gone it, with 4K miles and only one year old, can't bring myself to do that. Besides, would cut into my Denali LED auxiliary lights fund ... for replacing the factory Hella's.
 
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