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Fixing a KX500 rear brake lever
Posted: Wed Jul 22, 2015 4:22 am
by Sandblaster
I have 6 KX500 rear brake levers in inventory.
Every one of them has the same issue.
- 2000 kx500 kawasaki rear brake lever mod oem-cycle.com 101.JPG (400.43 KiB) Viewed 6111 times
The attachment point for the master cylinder gets wallered out and make for a sloppy rear brake
I'm gonna fix mine once and for all...
Re: Fixing a KX500 rear brake lever
Posted: Fri Jul 24, 2015 5:05 pm
by foxx4Beaver
funny, my buddy that made my drain plug and I were just discussing this topic in his garage last weekend.
he works as a machinist, and plans on making a stainless steel press-in collar to try.
and if it doesn't work out like he thinks/hopes, he's got another plan.
Re: Fixing a KX500 rear brake lever
Posted: Fri Jul 24, 2015 7:42 pm
by Sandblaster
Yep.... I also considered doing that as it would work just fine.
But, I'm going to try something a little different
Kinda goes along with my personality
Re: Fixing a KX500 rear brake lever
Posted: Mon Aug 03, 2015 9:19 pm
by Sandblaster
Re: Fixing a KX500 rear brake lever
Posted: Mon Aug 03, 2015 9:23 pm
by Sandblaster
To fix it I drilled out the existing hole to make it round again.
Then I cleaned it extremely good.
Next, my welder filled in the hole and added a bit of material around the outside edge where the bearing is as it would be a little too small for the bearing to fit.
Then I drilled a 16mm hole for the bearing.
Slipped the bearing in with a bit of bearing retainer.
DONE!
Oh! Bearing size:
16mm OD x 8mm ID x 5mm wide
Next I need to give it a good ride and see how it holds up.