BMW R1200RT/R1250RT Forum

Could the thread on the plunger be dressed up using a die. The grub screw in the barrel could be drilled out and threads re-tapped, together with the thread for the plunger. Or, drill out both threads and fit Time-Serts to repair the threads. Alternatively, have a new barrel manufactured. All good ...

I'm confused (easily done), were the plungers removed without removing the grub screws, then screwed back in. Yes, when I went to tighten the brake grub screw after threading in the plunger it was stuck fast and rounded out the hex. As it happened the thread on the plunger was a little burred so lo...

David. wrote: ↑Sat May 25, 2024 8:19 pm Were the grub screws removed from both the brake and clutch levers, with the plungers being removed and reused in the replacement levers.

Yes, but I couldn’t remove the locking ones, I should of left it at a half turn really it’s a very strange setup to be honest.

sakm wrote: ↑Sat May 25, 2024 6:26 pm I believe its all part of the plunger so you can't just replace the grub screw

Ahh yes your correct, I did adjust it using pliers but marked it up a little, I’m getting careless in my old age

David. wrote: ↑Sat May 25, 2024 7:20 pm Is it the plunger adjuster or grub screw in the barrel which is rounded out.

Plunger.JPG

If it's the grub screw, this might do the trick, https://a2stainless.co.uk/product/m4-x- ... in-914-a2/

Both!, are you thinking drill them out and try and re tap the threads ?.

sakm wrote: ↑Sat May 25, 2024 10:48 am What do you mean you have messed it up?

Rounded out the 2mm Allen grub screws as they were very tight with loctite on the brake side, the clutch side was fine. It’s usable but I’d rather replace it.

So after swapping my levers over I managed to mess up the tiny 2mm Allen grub screws you have to loosen ( covered in red threadlock) , I thought each part could be purchased separately having read another forum but the dealer said unlikely as it looks like that plunger rod is part of the master cyli...

sakm wrote: ↑Sun May 19, 2024 8:39 pm Not sure what's going on there! I will have a look and see if I can see anything

Just retaken them on my iPad instead of iPhone, they uploaded fine but are not the way around I took them. Odd!

sakm wrote: ↑Sun May 19, 2024 8:39 pm Not sure what's going on there! I will have a look and see if I can see anything

Cheers, no idea lol, just images from my iPhone, it didn’t say file to large etc.

No idea why images don’t upload properly?

So went with ASV in silver, happy but watch out with swapping parts over as those BMW 2mm Allen grubs covered in loctite are ….

So I went with ASV standard length levers in silver, very happy with the outcome, just be careful when swapping the barrel and pushrod of those 2mm Allen grubs covered in loctite

Steve398 wrote: ↑Wed May 15, 2024 3:16 pm Why’s that girl behind you looking at your bum Martin?

It was actually a bloke Steve… I have often wondered that

Zx10, B12.

A few I built/ modified over the years,
GPZ1100, ZX10, Bandit12.