E brake reverse mod how to FINALLY

[kinger]

Hello all

I promised this 3 years ago but finally completed today. It starts from this thread and betheviper gets the credit for the idea I'll take the credit for the write up [emoji846]

Thread from 2014:
http://ty4stroke.com/threads/handle-bar-reverse-mod.59070

This mod only costs time and saves 2.4lbs by eliminating the reverse lever and converting the E-brake cable lever to put it in reverse.

Start with taking your stock E-brake off and cutting off the tab that the cable screws into:

Also disassemble the part that that cable end fits into:

Next up will need to remove our chaincase to make things easier. You need to mount the cable end piece to the footwell. Mount the center of the hole about 7/8" from the rivet in the footwell:

The end should look like this I just used a small bolt and lock nut. Also notice the wing with the little hole in it is resting against the rivet so it doesn't rotate:

Next you need to mount the nub you cut off to a small piece of aluminum unequal angle (.75"X1"). Lay the piece on there and cut out the aluminum angle to match the nub.

I had to use two small rivets 1/8" body. I also had to recess the 2nd rivet because the nub was so thick. This mounted the nub to the angle. It doesn't need to be stronger it's just holding it there and always has down pressure on it:

Next mount the angle to the lever actuator on the chaincase. I had to drill one small hole through the steel.

Next assemble the chaincase and be ready to fight the cable end getting it in place. I found it easiest to start the barrel and then pin in place with a flat head screwdriver by prying it against the chain case.

Final installation:

Use a 8mm to adjust the cable 'throw' I had to have mine screwed all the way in and it's perfect. Actually much easier to put in reverse than the lever! My beef was the lever freezing up all the time. Looking forward to this!

Parts removed and weight saved:

For a parking brake I take a small bolt and put it in behind the hydraulic brake holding the brake lever on. Worked much better than the e brake ever did.

Have fun!!!



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[slowride06er]

Thanks for the mod and pics it may take me three years to do this but its saved in a good spot. This site rocks

 

[kinger]

Don't wait 3 years like I did! LOL I just used it again yesterday...SO SLICK!! I love this. I even mounted the sensor up on the bar so the horn beeps AND of course the E-bake handle is in the way of the brake so I should avoid any accidents LOL.

 

[kinger]

OMG got to try this out on the trails after our recent blizzard, its SO COOL! Why did I wait this long? Backing out of my trailer is simple and so fluent since your hand is up by the brake anyway, I just backed out, barely stopped flipped the lever and went forward all in one motion. This is a sweet mod!

 

[slowride06er]

Question do you still have a backup alarm?

 

[kinger]

Not right now. I plan to move the switch to the bars so the ebrake lever depresses the switch to activate the alarm. Although after using it, its deadly obvious its in reverse as your hand lays on it to activate the brake. Ill probably do the horn in case others ride it though.


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[slowride06er]

My xlt never had a alarm. It had a very similar set up that you now have just opposite side. I bout that sled in 96 and never bought a sled without it since. I'd like to rig it up as a horn. Horn would be used for those extended trail stops when its time to get going.

 

[kinger]

Backed the sled into the garage for the first time and still smiling with this mod. Its so easy and fast. I'll work on the buzzer this year.

 

[zx4ever]

Thanks for the inspiration kinger. I finally got this done and it is awesome, highly suggest doing this to anyone on the fence. My mod was on a Nytro and I did it a little different but the theory is the same.