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Brake lever hiting delkevic 4 into 1

  • Thread starter Thread starter Dre
  • Start date Start date
D

Dre

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I just purchased/ installed a new Delkevic 4 to 1 for my 83 GS1100G and I couldn't be happier. With this new system and the replacement of my manifold o rings I have managed to resolve all my poor idling issues. She runs great and no more stalling at lights.

The problem I'm having is that my foot brake lever is hitting the can when I fully apply the brake. I've tried raising the lever but then it's just too high. I'm a tall guy (6'5) and the foot rests are high enough as is. I've looked online for a shorter lever but can't really see one that will fit. Maybe I'll need one fabricated ?
 
yep, very hot! sometimes they bend ok, sometimes they just snap. worth a try if you gonna have to get a new one anyway.
 
I had bent my lever out just to get it to line up under my boot better. I didn't heat it but it's cast and could be broken pretty easily. I had a spare from a parts bike just in case. I don't have a 1100 but there is plenty of room under the lever on my bike to the pipe. I'm just wondering why it doesn't clear if it was designed for your bike. Pictures would help.
 
That certainly looks tight. Is it possible to get a full picture of the system on the bike. Something doesn't look right there.
 
turn your hang bracket around where it bolts to the muffler, it should give you more clearance. I would loosen all bolts a little until you get it into position. The muffler might have to be slipped back a little also.
 
Last edited:
OldVet66 said:
turn your hang bracket around where it bolts to the muffler, it should give you more clearance. I would loosen all bolts a little until you get it into position. The muffler might have to be slipped back a little also.
Click to expand...

Tried that. Didn't work
 
Heat and bend as suggested. My exhaust has a depression in the muffler for clearance in that area.
 
You can grind 1/4" off the bottom of the lever. That should give you the clearance without weakening the lever much.
 
I have done the same thing on brake pedals for more clearance as well as grinding some meat off the bottom of the footpeg to allow the pedal to travel a little further up.
Then re-bleed the system to remove any and all excess pedal travel/sponginess.
 
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