BX-1000 Black Max fill plug ussue

[Bob Wood]

I am running this gear set up per Leonards plans on my XL which I am a week or 2 from firing up for the first time. I go to fill the fluid in the master and find I cannot get the fill plug out without taking the brake lever off.....Cannot be right?? I pulled it every way with the hex wrench trying to turn the plug. Not enough clearance....I have a call into the plant....

Anybody else see this,
Bob

[Sam Buchanan]

Just take an extra hex wrench you have laying around and cut one leg short enough to fit between the lever and plug.

[Bob Wood]

Sam sorry  I was not too clear. I can get the wrench in and turn it ok but the back of the plug runs into the lever bottom before it is half way out. I am going to talk to the company before I grind off 1/16" off the lever bottom. 
Thanks. Bob

[Sam Buchanan]

Does your lever look like this?

[Bob Wood]

Yes Sam that is it, bought it last summer.  When mounted like yours when the lever is pulled back there is not enough clearance between the top fill plug and the side of the lever bottom...The screw plug runs up tight against the lever, no matter the lever position. cannot even back it 1/2 way out

Very odd.....
Bob

[Sam Buchanan]

Yes Sam that is it, bought it last summer.  When mounted like yours when the lever is pulled back there is not enough clearance between the top fill plug and the side of the lever bottom...The screw plug runs up tight against the lever, no matter the lever position. cannot even back it 1/2 way out

Very odd.....
Bob

Sounds like you will need to remove the lever and relieve it enough for the plug to clear. Or maybe you can file enough clearance with the lever in place.

[Bob Wood]

Sam,

Mystery solved, Black Max had a design change on the lever and an old one was sent on my master in error . They overnighted me one today.  Good people to work with. I am very impressed with this gear set up.

 
Thanks for the feedback, I am running your parking brake mod, very nice!,
Bob

[Sam Buchanan]

Sam,

Mystery solved, Black Max had a design change on the lever and an old one was sent on my master in error . They overnighted me one today.  Good people to work with. I am very impressed with this gear set up.

 
Thanks for the feedback, I am running your parking brake mod, very nice!,
Bob

It's always good to find out we haven't lost our mind.......  

Having the parking brake is almost reason enough to install the Black Max system. Don't attempt to leave home without it......