TUSK Folding Lever Set Instruction Manual

1. Introduction

Thank you for choosing the TUSK Folding Lever Set. This manual provides essential information for the proper installation, operation, and maintenance of your new levers. Designed for durability and performance, these levers are a direct replacement for your motorcycle's original equipment.

Image 1: TUSK Folding Lever Set, main view. This image displays the black TUSK folding lever set from a top-down angle, highlighting the TUSK logo and the folding mechanism.

2. Safety Information

Always prioritize safety when working on your motorcycle. Improper installation or maintenance can lead to serious injury or damage. If you are unsure about any step, consult a qualified mechanic.

• Ensure the motorcycle is stable and secure before beginning any work.
• Wear appropriate personal protective equipment, including gloves and eye protection.
• Do not operate the motorcycle with improperly installed or damaged levers.
• Regularly inspect levers for wear, damage, or loose fasteners.
• Keep all fasteners tightened to manufacturer specifications.

3. Compatibility

This TUSK Folding Lever Set is specifically designed for the following Honda motorcycle models and years:

Image 2: Compatibility Chart. This image shows a table detailing the compatible Honda models and their respective year ranges for the TUSK Folding Lever Set.

4. Package Contents

The TUSK Folding Lever Set package includes:

• 1 x TUSK Folding Clutch Lever
• 1 x TUSK Folding Brake Lever

5. Setup and Installation

5.1 Tools Required

• Appropriate wrenches or sockets (typically 10mm, 12mm, 13mm, or 14mm depending on your motorcycle)
• Screwdriver (Phillips or flathead, as needed)
• Torque wrench (recommended for proper fastener tightening)
• Grease or anti-seize compound
• Clean rags

5.2 Installation Steps

1. Prepare the Motorcycle: Ensure the motorcycle is turned off and securely placed on a stand.
2. Remove Old Levers:
   • For the clutch lever, loosen the clutch cable adjuster and remove the pivot bolt. Disconnect the clutch cable from the old lever.
   • For the brake lever, remove the pivot bolt. Carefully disconnect the brake light switch wire (if applicable) and ensure the brake master cylinder plunger is free.
3. Inspect and Clean: Clean the perch and pivot areas thoroughly. Inspect for any wear or damage.
4. Install New Levers:
   • Apply a small amount of grease to the pivot points of the new TUSK levers.
   • For the clutch lever, connect the clutch cable to the new lever and insert the pivot bolt. Adjust the clutch cable for proper free play.
   • For the brake lever, ensure the master cylinder plunger aligns correctly. Reconnect the brake light switch wire (if applicable) and insert the pivot bolt.
5. Tighten Fasteners: Securely tighten all pivot bolts and fasteners. Refer to your motorcycle's service manual for specific torque specifications.
6. Test Functionality: Before riding, thoroughly test both the clutch and brake levers to ensure smooth operation, proper engagement, and disengagement. Verify that the brake light activates correctly.

Image 3: TUSK Folding Lever Set in folded position. This image shows the lever folded upwards, demonstrating its impact-resistant design.

6. Operating Instructions

6.1 Lever Adjustment

The TUSK Folding Lever Set features grip-distance adjustability for personalized comfort and control. To adjust the lever reach:

• Locate the adjustment screw or dial near the lever pivot point.
• Turn the adjuster to move the lever closer to or further from the handlebar.
• Test the feel and ensure comfortable reach and full engagement/disengagement of the clutch or brake.
• Ensure the adjustment mechanism is secure after setting your preferred position.

Image 4: TUSK Folding Lever Set, rear view. This image provides a view of the lever from the rear, showing the adjustment mechanism and the overall robust construction.

7. Maintenance

To ensure the longevity and optimal performance of your TUSK Folding Lever Set, follow these maintenance guidelines:

• Regular Cleaning: Clean the levers regularly with mild soap and water to remove dirt and debris. Avoid harsh chemicals that may damage the anodized finish.
• Lubrication: Periodically apply a small amount of appropriate grease to the pivot points and the folding mechanism to ensure smooth operation and prevent wear.
• Inspection: Routinely check for any signs of wear, cracks, bends, or loose fasteners. Pay close attention to the folding mechanism and pivot bolts.
• Adjustments: Verify that the lever reach adjustment remains secure and that the clutch cable and brake system have proper free play.

8. Troubleshooting

This section addresses common issues you might encounter with your TUSK Folding Lever Set.

9. Specifications

Detailed specifications for the TUSK Folding Lever Set:

10. Warranty and Support

For warranty information or technical support regarding your TUSK Folding Lever Set, please refer to the official TUSK website or contact your authorized TUSK dealer. Keep your proof of purchase for any warranty claims.

For further assistance, you may visit the TUSK Powersports Store.