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Posted by: oldyeller
I haven't had any luck finding smaller levers.If you look in my pictures you can see an easy modification that I did to hold the lever closer to the bars.I just adjusted the cables with a little slack so there was room for the metal bracket to hold the lever in without applying the brakes but applies them as soon as the lever is pulled.Make sure the piece of metal is centered so the cables won't wear against the edge of the metal.The nice part is that once their hands get bigger you can just take the little bracket off and return the bike to normal.
Posted by: oldyeller
Yeah it should work on both sides unless it interferes with the safety starting switch or leaves the brake light on like you say.Our Viper has a hydraulic brake on the rear so I couldn't use that trick on the left side.
Posted by: mywifesquad
Years ago I had the same problem with my boys. I took one of those nuts that go on the valve stem of a motorcycle tube valve and cut thru one side with a hack saw. I slipped the nut over the cable between the lever and the bracket. I used 2 in the begininning and then took them out as the kids grew.
Posted by: mywifesquad
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Originally posted by: BMazz007
what do you do with hydrolic brakes i was just going to start a post about this for my kids new atvs how do you move the lever closer?
I'll look at my Jetmoto tomorrow and see what I can come up with.
Posted by: mywifesquad
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Originally posted by: chipster314
Thats a good idea also. I might try to improve on that and use a hard rubber washer so it does no damge the cable at all.
Thats a good idea too. I used the valve stem nutas because they were thin. And they were also made of brass, which is a fairly soft material.
Posted by: mywifesquad
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Originally posted by: BMazz007
wHAT ABOUT FOR HYDROLIC BRAKES?
I was at Jetmoto yesterday talking with Eugene about your question. Im going to be modifying a couple of levers and would like you to test them for me. If your interested pm me your address and ill ship them to you when I finish them. It could be a week or so. Also what brand/size quad is it for and which lever is it? Or is it both sides? Thanks, MWQ
Posted by: mywifesquad
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Originally posted by: RAMTechRC
I'm trying to figure out a hydraulic rear brake lever for the SunL 50-95 that Raceway sells. Its about 3" away, and I need at least 1" closer.
John at Racewayatv is sending me a lever assy for the SunL quads and im going to either modify the existing lever or cut a whole new one. Ill be posting my results here.
Posted by: mywifesquad
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Originally posted by: RAMTechRC
OK, great. I just got a new one from Raceway on Friday. Be careful, its potmetal, and doesn't like to be machined or bent!!!
I wasnt going to try and bend it, but what happens when you machine it?
Posted by: mywifesquad
Thanks RAMTechRC, ill get out the 6 flute carbide, and go slow.
Posted by: mywifesquad
I finally got a few lever assy's from John at Raceway. I have modded 1 lever so far. And its 1" closer to the handle bar. I did it by removing material from the "nub" that sticks out and activates the master cylinder. I need to add a little boss that will activate the ign cut off switch and then can send it out to BMazz007 some time next week. It is fairly simple to remove the material necessary. I used a belt sander. but a file would work too. The tab could be added a few different ways but I will bolt it on. If some one wasnt concerned about the ignition cut off they could just file the material away until it worked. Im just not to sure if removing the ign cut off on a kids quad is very wise and Im definitely not going to be the one to reccomend it.
Posted by: mywifesquad
BMazz007, PM me your addrees and I'll get the modified lever in the mail wednesday nite.
Posted by: mywifesquad
Bump
Posted by: mywifesquad
BMazz007, you should be getting the lever in the next day or so. I was in such a hurry I forgot to put a note in the box. Let me know what you think and Ill be getting a copy of it to Jetmoto to make a production version. Or let me know what you would change and I'll try that next.
oldkawi, that sounds like a good idea, have you done it before?
Posted by: mywifesquad
Thanks for the input oldkawi, I am going to ask for one of those levers the next time I go into a m/c shop.
Posted by: RAMTechRC
I made the mistake of trying to heat and bend my Chinese SunL brake handle. I thought they were aluminum, but they were actually pot metal.
Posted by: RAMTechRC
I'm trying to figure out a hydraulic rear brake lever for the SunL 50-95 that Raceway sells. Its about 3" away, and I need at least 1" closer.
Posted by: RAMTechRC
If you are only going to have one brake, its better to be onthe left. I took mine apart and looked at machining a new bracket. Too much hassle so far. I may try and get another brake handle and see if I can machine it at a different agnle and bolt it together.
Posted by: RAMTechRC
OK, great. I just got a new one from Raceway on Friday. Be careful, its potmetal, and doesn't like to be machined or bent!!!
Posted by: RAMTechRC
Its like machining sand. Flakes apart. Try a 4 flute endmill, that may work better.
Posted by: oldkawi
Why not use an emgo rubber / plastic handle, heat it with a heat gun, bend it to the applicable shape and go with that??
Posted by: oldkawi
yes,recently for a 5 year old on a gio 50 an old 2 stroke quad of near unknown manufacture, (mitey mite 50?) Kasea?) on a honda 70 atc, a honda 90 atc, a zinger 60, and zinger 4 - 80 its not hard to do and a lot cheaper to replace emgo than OEM, when you sell it put the OEM back on, and no ones the wiser.
Posted by: oldkawi
take the lever off go to a dealer and get the closest match to your needs grind off the excess in the attachment point, then heat and form to the shape you want, untill you figure out how to do it; plan on screwing a few up, once you have a method down it works pretty simply.
Posted by: BMazz007
what do you do with hydrolic brakes i was just going to start a post about this for my kids new atvs how do you move the lever closer?
Posted by: BMazz007
thanks my wifesquad im thiking of somthing too.
Posted by: BMazz007
wHAT ABOUT FOR HYDROLIC BRAKES?
Posted by: BMazz007
THATS REALLY NICE OF YOU GUYS ! THANK YOU HERE EMAIL ME I CANT GET YOURE TO COME UP MINE IS BMAZZ007@OPTONLINE.NET
Posted by: BMazz007
mINE IS ON THE LEFT ALSO ON OUR FREDOM 70S WE HAVE TO GET ANOTHER WHOLE ASSEMBLY BECAUSE ONE OF THE NEW ONES HAS A LITTLE HAIRLINE CRACK IN THE MASTER CYLINDER AND THE BRAKE ISVERY SOFT BECAUSE OF THE CRACK AND FLUID IS LEAKING OUT, ITS A VERY SMALL AMOUNT BUT ITS LEAKING. I CONTACTED THE DEALER AND I WAITING TO HEAR FROM HIM THEY SHOULD BE SENDING IT OUT ANYDAY. ILL CALL CONTACT THEM ON MONDAYTO FIND OUT THE STATAS. DO I NEED THE WHOLE ASSEMBLY OUR CAN I JUST GET THE MASTER CYLINDER/
Posted by: BMazz007
Awsome it sounds like you did a nice job i have two kids i will let the one with the smaller hands give it a try!!!!! let me know ill send you my address.
Posted by: Jester125
Same here, my son is really having a hard time with his brake lever, 1 inch closer would be perfect. I tried to come up with a solution for his Sunl 90 but with no luck, also does anyone find it strange that the brake lever is on the left side ?
Chris
Posted by: Jester125
Could you tell me where and which emgo model lever to buy it.
Thanks, Chris
Posted by: chipster314
Looking for a handle that is bent in closer to the bar. my little girls hands are on the small side and looking to make it easier for her.
Thanks
Posted by: chipster314
Thats a good idea, I was thinking of some sort of wedge in there but yours looks good. Think that would be possible with the left side also. Only problem I forsee is the break light being on all the time. Guess i could just take out the bulb for now.
Posted by: chipster314
Quote
Originally posted by: mywifesquad
Years ago I had the same problem with my boys. I took one of those nuts that go on the valve stem of a motorcycle tube valve and cut thru one side with a hack saw. I slipped the nut over the cable between the lever and the bracket. I used 2 in the begininning and then took them out as the kids grew.
Thats a good idea also. I might try to improve on that and use a hard rubber washer so it does no damge the cable at all.
Posted by: chipster314
Ok Guys/Gals , this is what I did, I bought some hard rubber plumbing washers slit them and put them around the cable between the lever and the hard stop, and adjusted the back brake with the easy wing nut at the rear so it was not grabbing. On the front I had to remove the two jam nuts as there was now adjustment left to loosen off the brake tension, placed a washer on each cable and that was it. Moved the levers in about 1/2-3/4". I would say the washers were about the size of a 1/4" inch flat washer and about 3/16" thick.
I must stress you need to realy check your brake adjustment after this as if you move it in to far you will not have enough movement to apply proper braking
Actualy this is what it says on the card for the washers
rear brake I used 1/4L Flat washer used for faucet
front brakes I used 1/4l Beveled washers used for faucet (A Little Thicker) need two washers on the front one on each cable
