ASV Levers issues

Discussion in '5th Generation 1998-2001' started by GaryN, Jul 8, 2021.

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  1. GaryN

    GaryN New Member

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    Anyone have any experience with ASV levers? I bought a set. Clutch works fine. The brake side locks the front wheel because the fit is off. In their kit, they provided a Honda push rod/plunger, which I missed. Been asking them for two weeks about what to do with it. Not the best in customer service for sure.

    Part of the problem is the ball end of the stock push rod/plunger is too big for the socket of the ASV lever. So, it makes the push rod 'longer' and hence applies enough pressure to engage the front brake. Their push rod is totally different looking that what's used on our bikes. Theirs is just a straight piece of metal without seals, etc.

    I'm reluctant to go tearing things apart just yet since I just got the bike back together after a number of months of working on upgrades and repairs. And I'm not sure I trust these guys.

    The manual does not indicate the rubber seals of the stock rod/plunger come off. And the arts diagrams shows the stock rod/plunger as one piece as well.

    At first I was told they didn't make levers for a '99. I pointed out their web site disagrees. Then, after numerous pictures sent to then, I was informed I have the correct set. Yet, so far no one knows about their plunger rod provided. Very strange.

    Wish CRG made a set for a '99. Way better parts. At this point I'm just trying to salvage a bad purchase. But that may not be possible.

    Any other levers to consider, just in case?

    Thanks for any help!

    Gary
     
  2. Terry Smith

    Terry Smith Member

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    Just a thought...the stock pushrod I believe has different ends and if inserted the wrong way round, has a tendency to lock the brake up. Or so I've heard.
     
  3. fink

    fink Member

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    pictures would be very handy.
     
  4. fink

    fink Member

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    The same levers fit the Blackbird, CB1300,CB1100,CB400, Varadero. ASV part numbers for std levers BRC541 and CRC 545 C5 series.
     
  5. KarlR

    KarlR New Member

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    Gary,
    I just had the same problem on my 99.
    First, the lever and bushing fit to tight in the MC, so I used a fine file to lower the ridge on the bottom of the lever where the bushing rides. This made the lever pivot smoothly.
    Second, I filed down the ASV supplied plunger so that it wasn’t applying the brakes. It was only about a 1/32”. You don’t want to take off to much because it would leave play in the lever.
     
  6. GaryN

    GaryN New Member

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    Karl, I did the same thing to the lever. Definitely needed some filing. But my issue is wondering how to pull the stock plunger out of the master cylinder. I didn’t try to install the supplied new plunger yet. Can you just pull the stock one out?

    Thanks.

    Gary
     
  7. KarlR

    KarlR New Member

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    Yes, it pulls right out. The rubber dust boot kind of holds it in.
     
  8. GaryN

    GaryN New Member

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    Thanks. My dust boot is looking a little meek at the moment. Will just have to be careful.

    And just got the same answer back from ASV. Only took two weeks.

    Gary
     
  9. w3bdevil

    w3bdevil New Member

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    Just my 2 cents. I also have a '99 5th gen and I installed ASV short levers with the supplied parts and instructions. No need to modify anything and everything works perfectly.
     
  10. GaryN

    GaryN New Member

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    The problem was I didn’t see the rod they provided. Big difference in size. All is well now. I was worried about getting the stock plunger rod out. Didn’t realize it was a simple pull out. My boot is a mess though. I was most worried about destroying what was left of it. Hopefully it can be replaced easily. Just ordered one.

    Note: Revzilla has these in stock. Good place to order small OEM parts like nuts and screws for our bikes. No shipping charges on lots of the small stuff. Usually, you buy a $5 part and shipping is like $8!

    All in all, this qualifies as - oh stupid me.

    Gary
     
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