To replace a mechanical brake lever on your ebike, particularly if you're dealing with a Perraro Electric Bike or similar, you'll need to follow a detailed process. This guide is intended for those with mechanical brake systems. If your bike has hydraulic brakes, you'll need to refer to a different guide.
Tools Needed:
- Flat head screwdriver
- Isopropyl alcohol
- Paper towel
- Flat side cutters
- 3 mm Allen wrench
- 5 mm Allen wrench
- Torque wrench with 3 mm and 5 mm Allen bits
- Zip ties
- Replacement brake lever (specific to your ebike model)
Steps to Replace the Right Brake Lever:
1. Prepare the Bike
- Turn off the bike, remove the battery, and press the MODE or Power button to discharge remaining power.
2. Remove the Handlebar Grip
- Use a flat head screwdriver to pry off the grip end cap.
- Twist and pull the grip off. If it's tight, apply a bit of rubbing alcohol between the grip and handlebar as a lubricant.
3. Remove the Throttle (For Right Brake Lever Replacement)
- Trace the throttle cable to its connector, snip any zip ties, and unplug the connector.
- Use a 3 mm Allen wrench to loosen the throttle clamp bolt and slide off the throttle and spacer, noting the spacer's orientation for reassembly.
4. Remove the Old Brake Lever
- Add slack to the brake cable at the caliper using a 5 mm Allen wrench.
- Align the barrel adjuster and lock nut slits with the slot on the brake lever housing.
- Remove the brake cable from the lever and unplug the brake connector.
- Loosen the brake lever clamp bolt with a 5 mm Allen wrench and slide off the old lever.
5. Install the New Brake Lever
- Slide the new brake lever onto the handlebar, adjusting it to match the angle of the other lever. Tighten the clamp bolt with a 5 mm Allen wrench and torque as specified in your Owner's Manual.
- Reconnect the brake connector, ensuring notches and pins are properly aligned.
6. Reinstall the Brake Cable
- Line up the barrel adjuster and lock nut slits with the lever housing slot.
- Insert the cable stop into the lever mount and thread the cable through the slits.
- Secure the cable housing in the barrel adjuster and tighten the lock nut against the lever housing.
7. Adjust Brake Cable Tension
- Pull the brake cable taut at the caliper and tighten the pinch bolt with a 5 mm Allen wrench, torquing to the specification in your Owner's Manual.
- Test the brake lever's reach and adjust if necessary.
8. Reinstall the Throttle (If Removed)
- Slide the throttle and spacer onto the handlebar, ensuring correct spacer orientation. Tighten the clamp bolt with a 3 mm Allen wrench and torque as specified.
- Reconnect the throttle connector, aligning notches and pins.
9. Reinstall the Handlebar Grip
- Apply a small amount of isopropyl alcohol to the handlebar and slide the grip into place. Reinstall the end cap. Ensure the grip is secure once the alcohol dries.
10. Final Touches
- Replace any snipped zip ties to secure the cables neatly.
- Reinstall the battery and perform a thorough test of the bike before riding.
Notes:
- If replacing the left brake lever, the process is similar, but you won't need to remove the throttle.
- Always refer to your ebike's specific Owner's Manual for torque values and other model-specific instructions.
- Regular maintenance and checks are crucial for ebike components, especially for bikes with mechanical brakes, as they may wear out faster than those on non-motorized bikes.
This guide should help you safely and effectively replace a mechanical brake lever on your ebike.
If you have any inquiries or need further assistance, feel free to contact our support team at support@perraroelectricbike.com or call us at (949) 414-8003.