can i use pre-2008 brake levers on a post-2008 front master cylinder? - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 11 Old 07-19-2013, 11:09 PM Thread Starter
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can i use pre-2008 brake levers on a post-2008 front master cylinder?

can i use pre-2008 brake levers on a post-2008 front master cylinder?

i noticed that the new levers have an adjustment screw, but will an older lever (pre-2008, with no adjustment screw) still fit (e.g. as a spare)?
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post #2 of 11 Old 07-19-2013, 11:23 PM
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Quote:
Originally Posted by loupiote View Post
can i use pre-2008 brake levers on a post-2008 front master cylinder?

i noticed that the new levers have an adjustment screw, but will an older lever (pre-2008, with no adjustment screw) still fit (e.g. as a spare)?
Hi loupiote!
Sorry, no can do they are too different. I tried to make a spare Gen2 lever fit my Gen1. Even with grinding and such I couldn't get it to work. What you need is to swap on the Gen2 mastercylinder if you want the adjustable lever.
Sorry Charlie....uh loupiote!
Regards....justjeff

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post #3 of 11 Old 07-20-2013, 12:15 AM Thread Starter
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Originally Posted by justjeff View Post
Hi loupiote!
Sorry, no can do they are too different. I tried to make a spare Gen2 lever fit my Gen1. Even with grinding and such I couldn't get it to work. What you need is to swap on the Gen2 mastercylinder if you want the adjustable lever.
Sorry Charlie....uh loupiote!
Regards....justjeff
ah, ok, good to know.

in fact, it looks like my (Gen1) master cylinder is getting bad. it is letting the lever "sink in" when depress it slowly. no leak outside, but it looks like the first seal is leaking (inside), so i was looking at replacing the whole master cylinder (seems to be easier than replacing the seals, and good used master cylinders seem to go for about $50, but most of the best ones are Gen2 of course. which means that i will need to get a couple of new levers, too, if i decide for a Gen2 (i always like to carry a spare lever).

do you think i should buy one of the aftermarket seals kit on ebay? or would you recommend rather getting a good Gen2 used master cylinder?
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post #4 of 11 Old 07-20-2013, 12:29 AM
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I have both a Gen1 and a Gen2. If my Gen1 master starts giving me trouble I would look for a Gen2 because I want the adjustable lever too. I have short fingers and find the reach on the Gen1 MC a little long. I already ground the contact point on the Gen1 lever so the lever is closer to the grip but the adjustable lever is the way to go. You have the perfect excuse and opportunity to upgrade tho the Gen2 for little more than the cost of seals.
Regards....justjeff

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Woooo WOOOOO!!!!!
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post #5 of 11 Old 07-20-2013, 01:00 AM Thread Starter
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Originally Posted by justjeff View Post
You have the perfect excuse and opportunity to upgrade tho the Gen2 for little more than the cost of seals.
yeah, that's what i'm thinking.

i hope that at least the banjo screw is compatible!
[EDIT]

ouch.. not even! parts numbers are different. 92153 vs 920028

Last edited by loupiote; 07-20-2013 at 01:03 AM.
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post #6 of 11 Old 07-20-2013, 01:08 AM Thread Starter
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i hope the Gen1 brake line IS compatible with the Gen2 master cylinder?
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post #7 of 11 Old 07-20-2013, 08:39 AM
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I'll take a look at both bikes today and reply later with what I see. I believe both banjo bolts are 10mm so not sure why the different part numbers.
Regards....justjeff

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post #8 of 11 Old 07-20-2013, 02:30 PM Thread Starter
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thanks!
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post #9 of 11 Old 07-22-2013, 07:49 PM
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Hi loupiote!
I had a look at both my bikes and can't see any reason the gen2 master won't bolt up to the gen1 brakeline. They both look like 10mm banjo bolts to me. Of course when you do mods to things like brakes, it is up to you to make sure it is safe.
Sorry about the delayed response.
Regards....justjeff

P.S. The 92002B you quoted is the clamp bolt. The 92153-0627 is the banjo bolt and is common to both bikes.
jj

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Last edited by justjeff; 07-22-2013 at 08:49 PM.
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post #10 of 11 Old 07-23-2013, 12:40 AM Thread Starter
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ah, thanks, good to know.

sorry for the part number mistake
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