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Mechanical brake lever replacement guide for ebike

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.


  • 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.

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