Mikuni HSR 42/45/48 Throttle Lever - Latest Version

Additional Information

• Just bought a bike and discovered the throttle lever was broke and a zip-tie is holding the cable to the carb. The lever looks like this. Is this the HSR lever I need. How is this part installed? Can I do this? Are any special tools needed?

  This is the revised (stronger) throttle lever for the HSR. Whether or not you can replaced this throttle lever (bellcrank) really depends on your level of mechanical skill. This is not a particularly difficult job for a mechanic experienced with carburetors, but it could easily become too difficult for a hobbyist. There are several small parts, which are under spring pressure, and could be lost or damaged. The carburetor could also be damaged if the repair is not done correctly.
  To remove the lever, you would need to first unload the spring from the lever. This spring is under several pounds of pressure and care must be taken when removing the spring. Then, a very small drift of appropriate size must be used to carefully remove the pressed in split-pin holding the lever to the throttle shaft. Once the broken lever has been removed, it can be replaced with the new component.
  Place the new lever on the shaft, the hole on lever for the securing pin must be aligned with the hole on the shaft, and the pin reinserted through the part. This pin must be pressed in carefully or the throttle shaft will be bent. Finally, the spring must be preloaded and secured around the new lever.
  The only specialized tool will be a very small brass drift, approximately 2.0mm.

  Answer by: rick c (Admin) on Jan 6, 2020 1:27:00 PM