How to Replace or Swap Brake Lever Handles on Zoom HB-875/6 hydraulic brakes

I found the angled brake handles of the Zoom HB-875/6e hydraulic brakes to be not as comfortable as those of the smooth, non-sensored counterparts (the non “e” variants). I figured the handles had to come off somehow and they indeed do. I couldn’t find anything online about how to do it, so here is a small guide.

The pin that holds the handles into the lever assembly moves in one direction a few millimeters but seems to stop. The pin is held in by a plastic clip of sorts in the middle of the actual handle. Begin by figuring out which direction the pin moves towards. Press it out as far as it will go, then take a suitable screwdriver or similar to knock the pin out while supporting the handle.

Once the pin is most of the way out, use pliers to pull it out.

The pin should come all the way out along with the plastic locking clip in the middle. Next, use a 2mm allen to remove the adjustment post from the handle by turning the adjustment post clockwise.

Once this is through completely, the handle will come out completely, and depending on he version you have, the threaded cylinder that attached to the adjustment post may as well. Look out for the two washers that are on either side of the handle inside the lever frame.

This should pretty much be the reverse of the first process. Begin by ensuring the washers for the lever handle are inside the lever frame. Place the threaded cylinder that attaches to the adjustment post if it came out. Insert the handle into the lever frame and align the adjustment post to its threads. Thread the post into the cylinder by using the 2mmm allen wrench and rotating it counterclockwise.

Next, push the handle back into the frame and align the pin hole with the frame. You may have to play around a little to get the holes lined up.

Next, insert the plastic clip with the fingers facing down so the pin can align itself to the center when you place it in.

Place the pin through the lever frame until it stops against the fingers of the plastic clip. Finally, use a hammer to gently tap the pin back into the assembly and ensure it lines up flush on both sides.

Your threads may not be perfect and you may have trouble threading the handles back on to the adjustment post. Take care when doing this and ensure you have a good allen with no rounded edges to slip. I highly recommend not using a ball ended allen here. You will be sorry if you strip out the internal hex head of the adjustment post.